TECHNOLOGICAL FIELD
The present disclosure is in the field of cartridges for use in preparing a beverage.
BACKGROUND ART
References considered to be relevant as background to the presently disclosed subject matter are listed below:
- WO 2005/026018
- WO 2001/60219
- WO 2001/60712
- DE 102010047890
- EP 3216768
- WO 2017/214294
- WO 2012/031106
- WO 2010/138563
- WO 2002/080742
- WO 2002/080743
Acknowledgement of the above references herein is not to be inferred as meaning that these are in any way relevant to the patentability of the presently disclosed subject matter.
BACKGROUND
Machines for brewing a beverage using a disposable cartridge containing a dry beverage medium are known. A brewing machine for example, for brewing a beverage from a single serve filter cartridge is disclosed in WO 02/080742 and WO 2002/080743. The process is initialized by piercing the cartridge with tubular outlet and inlet probes. Then, a beverage is produced by inserting a heated liquid into the cartridge that is combined with the dry beverage medium and the hot beverage is then extracted from the cartridge through the outlet probe.
A beverage filter cartridge is disclosed in WO 2005/026018. The cartridge includes a container which is divided by a cup-shaped filter element, formed from materials such as paper or polymer, into two chambers. Of these two, the top chamber, defined between the filter element and the cartridge's top, stores a dry beverage medium, such as ground coffee or other substances. The top of the cartridge container has a pierceable lid to allow liquid to flow into the top chamber, mix with the beverage medium and thus forming a beverage. The formed beverage then passes through the filter into the bottom. The bottom of the container is also pierceable to allow the beverage liquid to flow through and out of the cartridge.
Other examples of two-chamber beverage filter cartridges have been described in WO 2001/60219, WO 2001/60712, WO 02/082863, DE 102010047890 WO 2017/214294, WO 2012/031106, WO 2011/031294 and WO 2010/138563. A capsule for remineralizing water formed with an upper salt-containing space on top of a turbulence layer that may be made of or comprise a fibrous material is disclosed in EP 3216768.
GENERAL DESCRIPTION
The present disclosure has the purpose of providing a cartridge for the preparation of a beverage from a dry beverage medium. The dry beverage medium may be a solid, ground or particulate mass, such as ground coffee, instant coffee, tea, a solid composition for producing a health drink, solid base for a fruit drink, etc. The term “dry beverage medium” is intended to denote any medium, such as those mentioned above, that interacts with hot or cold liquid passing therethrough, such as water, to form a cold or hot beverage such as coffee, tea, flavored drink, etc.
The cartridge has a housing made of any suitable material, including a metal substance or alloy, such as aluminum, e.g. aluminum grade 8011, a polymeric material such as polyethylene, polypropylene, a recycled or recyclable material, biodegradable material, etc. As will be appreciated from the following disclosure, the cartridge's uniqueness is in its overall structure and is not limited by the material from which it is made. The cartridge, which has the overall shape of a truncated cone, has an internal space that is divided by a perforated wall element (may also be referred to herein in short as “perforated wall” or “perforated element”) into two chambers referred to herein has “first chamber” and “second chamber”.
The perforated wall element by some embodiments may be integral with one of the cartridge's elements. In some other embodiments the perforated wall element is formed by a perforated wall insert that is configured to be received and/or fitted within the cartridge's interior.
In use, as will be elucidated by the description below, the first chamber is on top of the second chamber—the water to be mixed with the beverage medium being introduced into the first chamber, typically by an inlet probe (e.g. tubular) that pierces the first chamber's closure (e.g. a film or a foil), reacting with the beverage medium to thereby produce a liquid beverage that then passes through the perforated unit (see below) into the second chamber and then out therefrom, for example through an outlet probe that pierces the bottom wall of the second chamber, into a beverage receptacle, e.g., a drinking glass.
The term “bottom wall” and the term “end wall” are used, interchangeably, to refer to the wall at the end of the cartridge, opposite its opening.
The terms “top” and “bottom” or corresponding terms, may be used to refer to the relative positions and/or orientations. When used in preparing a beverage, the first chamber is on top of the second chamber. However, in isolation the cartridge may be positioned with the first chamber being below the second chamber, the cartridge may be so oriented such that the two are horizontally arranged one next to the other, or any other orientation. The terms “top” and “bottom” may, thus, be used with respect to the cartridges orientation in its position when used in preparing a beverage. Similarly, the terms “downwards” may be used to denote directions from the first to the second chamber and the term “upwards” for the opposite direction.
The perforated wall element has bores or holes that are dimensioned such that they do not permit passage therethrough of the beverage medium, which is typically in the form of particulate solid, but permit a passage therethrough of water and beverage formed or brewed within the first chamber. There may, for example, be between about 10, 15, 20, 30, 40, 50, 75, or even 100 to about 150, 175, 200, 225 or even 250 holes in the perforated wall element and the holes may be all of the same diameter or some may have a different diameter than others. The holes may also be arranged in random or may be arrayed in any type of a 2-D array.
The term “about” as used herein means a value that may be within about 5%, 10% or even 15% from the stated value.
The cartridges may, for example, be configured to be used in beverage maker machines such as those disclosed in WO 02/080742 and WO 2002/080743 or in coffee makers such as those manufactured and marketed by Keurig Dr. Pepper, Inc., USA.
Thus, provided by one aspect of this disclosure is a cartridge for producing a beverage having a generally cup-shaped housing that is defined between an opening at one end sealed by a closure, an end wall at the other end and a side wall that is converging from the said opening towards said end wall in the general top-to-bottom direction such that the cartridge has a general shape of a truncated cone. The term “truncated cone” may be used herein to define a cup-shaped cartridge or a cup-shaped member, that has walls that generally converge in the top-to-bottom direction, and typically have smooth substantially continuous side walls without a bend or a shoulder; namely the side wall in cross-section defines a straight converging line that extends from the cartridge's opening to the end wall. This notwithstanding, a smooth sidewall may include some minor discontinuities in the overall smooth sidewall; for example: such formed by joining of two elements that together form the cartridge, as will be described below, as a result of pressure dents, etc. In the context of the cartridge, the term truncated cone also denotes the property of being able to be received in a cup-shaped receptacle of a beverage-producing machines such as those disclosed in WO 02/080742 and WO 2002/080743 or in coffee makers such as those manufactured and marketed by Keurig Dr. Pepper, Inc., USA.
The cartridge may be configured to fit within a cartridge receptacle of a beverage producing machine. A rigid perforated dividing wall element is disposed within the housing, dividing the housing's interior into a first chamber defined between said one end and the perforated wall element that comprises a dry beverage medium, and a second chamber defined between said perforated wall and said end wall. The perforated wall element may, according to embodiments of this disclosure, be integrally formed with an element of the housing; for example, in accordance with an embodiment of this disclosure, formed as an integral end wall of a first cup member that is combined with a second cup member to form the cartridge of this disclosure. According to other embodiments of this disclosure, the perforated wall element may be formed as an independent insert that is fitted into position within the cartridges.
The perforated wall element has holes or through-bores that are dimensioned to enable liquid to flow between the first chamber and the second chamber. As such, the perforated unit is configured to permit passage of liquid and block passage therethrough of the dry beverage medium. The perforated wall element may be planar, may be curved, may be dome-shaped (with domed portion pointing upwards or downwards), etc. The perforated wall element may, by some embodiments, be substantially horizontal, namely having a general orientation that is parallel to the rims of the opening and, hence, to the closure. However, in some embodiments the perforated wall may have another orientation, such as arranged in a plane that is angled vis-à-vis that defined by said rims.
The closure is pierceable by an inlet probe, typically comprising a tubular piercing element, for introducing liquid into the cartridge (e.g. hot water) and the bottom wall is configured to engage with a beverage outlet arrangement of the machine, for example a tubular outlet probe, for extracting the beverage from the cartridge.
The cartridge may have a side wall that generally converges from the top end to a narrower bottom end. The cup-shaped housing has, typically, albeit not exclusively, a rounded cross-section. In some embodiments, the cup-shaped housing may have an overall shape of a truncated conc.
The cartridge typically comprises a peripheral lip at its upper end to facilitate proper fitting into a beverage producing machine and the subsequent extraction.
In some embodiments, the housing is made of two cup-shaped members that are joined to one another, to be referred to herein as “first member” and “second member”. The first member has an opening at one end and may have a perforated wall at an opposite end and a first side wall extending therebetween. The second member has an opening at one end, a bottom wall at an opposite end and a second side wall therebetween. The two members are combined such that the opening of the second member is fitted onto said perforated wall of the first member, whereby (i) the opening of the first member constitutes said opening of the cartridge, (ii) the perforated wall of the first member constitutes said perforated wall of the cartridge, (iii) the end wall of the second member constitutes said end wall of the cartridge, and (iv) the first side wall portion and the second side wall portion jointly defining said side wall of the cartridge. Thus, the first member essentially defines the first chamber, and the second member defines the second chamber.
In some embodiments, when the first member is coupled to the second member the first and second side walls are complimentary to form a truncated cone shaped cartridge. As such, the first and second side walls define a substantially continuous side wall of the cartridge. Where the first member has a perforated end wall, it forms the perforated wall element within the housing that separates between the first chamber, defined substantially be the forts member, and the second chamber that is defined substantially by the second member.
The two members may be combined with/coupled to one another by fitting a portion of the second side wall adjacent to the second member's opening over a portion of the first side wall adjacent said perforated wall and tightly joining the two portions one to another. The two members may be joined to one another by welding, gluing, pressure joining, optionally with embossing, by screw-fitting, etc. This disclosure, as can be appreciated, is not limited to the manner in which the two members are joined to one another, which can be in any suitable manner. To ensure a gas-tight seal, a lubricant such as a food grade, silicone-based lubricant may be added between the two portions prior to joining.
In other embodiments, the perforated wall element may be formed by a perforated insertable element (which may be referred to herein also as “insert”) that is configured to be received within the housing's interior to divide it into said first chamber and said second chamber. The insert may be a generally planar element insertable into the cartridge's interior and seated on or fixed to features within the cartridge. For example, said insert may be fitted into position by attaching it to or seating it on projections or shoulder formed within the cartridge's interior. Where the housing is formed by two members that are joined to form said cartridge, consisting of a first and second cup-shaped members connected to one another at respective first and second connecting ends, one or both of the first and second connecting ends may have an inward-directed fold that defines said shoulder. The insert may, in addition or in the alternative, comprise a feature that is configured to tightly engage with a counterpart form-fitting feature in the cartridge's interior to secure it in position within the cartridge; for example through a snap engagement in which a strained feature of the insert may snap to engage a counterpart form-fitting feature within the housing's interior. In some embodiments, the bottom wall of the second member may be formed with a plurality of inner vertical ribs or projections circumferentially arranged such that their upper faces define a seat for said insert.
In some embodiments, the holes in the perforated wall element have a general shape of a truncated cone. The truncated cone shape may be defined between an upper hole end at said first chamber and a narrower bottom hole end at said second chamber; or may have a reverse orientation. For example, where the holes are formed by puncturing using a pinned surface, where the pins are generally cone-shaped between their pointed tip and their base, cone-shaped holes are formed. The side or the wall that faces the pins determines the orientation of the truncated holes; namely whether they converge from a wider dimeter in the side facing the first chamber to that facing the second chamber; or vice versa. The holes in other embodiments may be generally even throughout the span of the perforated wall, e.g. cylindrical. This latter embodiment of the perforated dividing wall may, for example, be achieved in casing process.
The cartridge may be a single serve cartridge for receiving a defined volume of water through the inlet probe that flows down through the first chamber, then through said perforated wall into the second chamber and for extracting a volume of a beverage through the outlet probe. A specific, albeit not exclusive embodiment of this disclosure is a cartridge for use in brewing a hot beverage, the dry beverage medium being suitable for such brewing, e.g., for preparing a coffee or a tea. The cartridge may be sized for a single serve drink or may be sized to permit the preparation of several servings (e.g. 2, 3, 4, etc.).
In some embodiments, the number and dimensions of the holes are configured to permit passage therethrough of the beverage produced in the first chamber at a rate such that the liquid introduced through the inlet probe will partially and transiently accumulate in the first chamber to properly wet the dry beverage medium. To achieve that, the number and dimensions of the holes, that define the rate in which the beverage that is produced in the first chamber is passed through the perforated wall into the second chamber, is matched to the nature of the dry beverage medium. Where, for example, the dry beverage medium has the effect of slowing the flow of water down towards the perforated wall, such as finely ground coffee, the dimensions and number of the holes may be configured to permit relatively rapid flow of the formed beverage therethrough; whereas, where, for example, the dry beverage medium is such that rapidly dissolves in the liquid, such as instant coffee, the dimensions and number of the holes may be configured to permit relatively slow flow of the formed beverage therethrough.
Provided by another aspect is an empty cartridge (namely a cartridge in which the first chamber is empty, and the opening is not sealed with the closure) that may be used to produce the cartridge disclosed herein. The empty cartridge has a generally truncated cone-shaped housing defined between an opening at one end and an end wall at the other end and a side wall. There is a perforated wall element within the housing, e.g. substantially parallel to a plain define by rims of said opening, that divides the housing's interior into a first chamber defined between said one end and the perforated wall and a second chamber defined between said perforated wall and said end wall. The perforated wall is the one defined above and it comprises holes that are configured to permit passage of liquid and block passage therethrough of the dry beverage medium. The empty cartridge is configured for further processing that comprises (i) receiving dry beverage medium into said first chamber, (ii) after said receiving sealing said opening with a closure, and is configured for (iii) fitting within a cartridge receptacle of a beverage producing machine, wherein said closure is pierceable by an inlet probe (e.g. tubular) for introducing a liquid and the end wall is configured for engagement with a beverage extracting arrangement of the machine, for example being pierceable by a tubular outlet probe of said machine, for extracting the beverage from the cartridge.
Also provided by this disclosure are cup-shaped members that are configured for combining with another cup-shaped member to produce the empty cartridge described above.
By an embodiment such cup shaped members comprise a first cup shaped member that comprises a first opening at its one end and a perforated wall, e.g. in a general plane parallel to the rims of the first opening, being with holes that are dimensioned to permit passage of liquid and block passage therethrough of a dry beverage medium at its opposite end and a first side wall extending therebetween that may, for example, have a general shape of a truncated conc.
Said first member is configured for combining with a second cup-shaped member that comprises a second opening at its one end, an end wall at its other end and a second side wall extending therebetween, that may also, for example, have a general truncated cone-shaped form, to form an empty cartridge. The empty cartridge may have a generally truncated cone-shaped housing defined between said first opening at its one end, said end wall at its other end and a side wall between the two ends defined by the first and second side walls, and having a perforated wall within said housing defined by said perforated wall, that divides the housing's interior into a first chamber defined by said first cup-shaped member and a second chamber defined by said second cup-shaped member. After such combining the so formed empty cartridge is configured for further processing that comprises receiving dry beverage medium into said first chamber, and after said receiving sealing said opening with a closure. The so formed cartridge is then configured for fitting within a cartridge-receptacle of a beverage producing machine, wherein said closure is pierceable by an inlet probe of the machine for introducing a liquid and the end wall being configured for engagement with a beverage extraction arrangement of the machine for extracting the beverage from the cartridge.
By an embodiment, such cup shaped members comprise second cup-shaped member that comprises a second opening at its one end, an end wall at its other end and a second side wall extending therebetween, that may, for example, converge in a top-to-bottom direction. Said second member is configured for combining with a first cup-shaped member that comprises a first opening at its one end and a perforated wall with holes that are dimensioned to permit passage of liquid and block passage therethrough of a dry beverage medium at its opposite end, and a first side wall extending therebetween, that may also be converging in a top-to-bottom direction, to form an empty cartridge having a generally cup-shaped housing defined between said first opening at its one end and said end wall at its other end and a side wall between the two ends defined by the first and second side walls; and having a dividing wall within said housing constituted by said perforated wall, dividing the housing's interior into a first chamber defined by said first cup-shaped member and a second chamber defined by said second cup-shaped member. Similarly as above, after such combining the so formed empty cartridge is configured for further processing that comprises receiving dry beverage medium into said first chamber, and after said receiving sealing said opening with a closure. The so formed cartridge may then be fitted within a cartridge receptacle of a beverage producing machine, wherein said closure is pierceable by an inlet probe for introducing a liquid and the end wall being configured for engagement with a beverage extraction arrangement of the machine for extracting the beverage from the cartridge.
Each of the cup shaped members may be formed with a generally laterally projecting lip around its opening. In some embodiments, the cup-shaped members are stacked for shipping to another location in which they are joined to form the empty cartridge. The lips may facilitate their eventual de-stacking. Such lips in the second members may be eliminated during the joining process, e.g. by the pressure applied in the case of pressure joining.
Provided by yet another aspect if this disclosure is process for the manufacture of an empty cartridge of the kind disclosed above. The process comprises producing two cup-shaped members and then joining them to one another. The first cup-shaped member has a first opening at its one end, a perforated wall with holes at an opposite end and a first side wall extending therebetween. The second cup-shaped member has a second opening at its one end, an end wall at its other end and a second side wall extending therebetween. Said second opening is dimensioned such so that ternal portion of the second side wall adjacent said second opening fit snugly over an external portion of said first side wall adjacent the perforated wall. Said internal portions are fitted over said external portions and such juxtaposed faces are joined to one another, which may be by welding, gluing, pressure joining, optionally with embossing, etc. In some embodiments, a lubricant such as silicone-based lubricant or any other type of sealing material, may be added between the two portions prior to pressure joining in order to ensure a gas tight seal between the two portions.
By one embodiment the perforation of the wall at the bottom end of the first member is carried out at the time of initial manufacturing of the first member. By another embodiment the production of the cup-shaped member comprises a separate step of puncturing holes through said wall. For example, such puncturing may comprise bringing a receiving surface of first element of a puncturing apparatus into contact with one face of said wall, the receiving surface comprising a plurality of cavities; displacing a pinned surface of a second element of said apparatus towards the opposite face of said wall, the pinned surface comprising a plurality of pins projecting towards the receiving surface, each such pin being opposite to one of the cavities in said receiving surface, each cavity being configured to receive at least an end of the pin therein, whereupon a plurality of holes are punched through said wall; and separating the first and second members from the so formed perforated wall.
By one embodiment, each of said pins is tapered, whereby the punched holes may have openings that have a dimension that is narrower at said one face than at the opposite face. The extent of penetration of the pins through the perforated wall may determine the dimensions of the holes, such dimension, in turn, may be matched to the types of dry beverage medium and may define the rate in which the beverage that is produced in the first chamber is passed through the perforated wall into the second chamber.
By other embodiments of this disclosure, rather than by puncturing, the holes may be made by drilling.
By another embodiment the holes may be formed at the time of casting the sheet or film from which the first member is formed.
Provided by another embodiment is a process, that comprises producing an empty cartridge having a generally cup-shaped housing defined between an opening at one end, an end wall at the other end and a side wall converging from said opening to end wall, the cup-shaped housing that is configured for fitting within a cartridge-receptacle of a beverage producing machine. Then a wall element insert is introduced that comprises holes that are dimensioned to permit passage of liquid and block passage therethrough of a dry beverage medium, into the housing and fitting it within the housing's interior to divide the housing's interior into a first chamber and second chamber, the first chamber is defined between said one end and said wall element, and the second chamber is defined between said wall element and said end wall, the perforated dividing wall element.
For the manufacture of a cartridge for producing a beverage a dry beverage is introduced into said first chamber, and then the opening is sealed with a closure.
SOME EMBODIMENTS
In the following section some embodiments will be listed in numbered passages intended to add onto the above description and not limit it in any way. The embodiments include such drafted in an independent format and other that dependent from such independent embodiments and may add additional elements to or modify embodiments from which they depend. Embodiments that are depended on one or more embodiments may also constitute elements that add to or modify other embodiments from which they do not depend.
- 1. A cartridge for producing a beverage comprising a housing having the general shape of a truncated cone defined between an opening at one end sealed by a closure, an end wall at the other end and a side wall converging from said opening towards said end wall; and
- a rigid perforated dividing wall element within the housing, dividing the housing's interior into a first chamber and second chamber, the first chamber is defined between said one end and said wall element and contains dry beverage medium, and the second chamber is defined between said wall element and said end wall, the perforated dividing wall element comprises holes that are dimensioned to permit passage of liquid and block passage therethrough of said dry beverage medium.
- 2. The cartridge of embodiment 1, wherein
- the housing comprises first and second cup-shaped members connected to one another;
- said first cup-shaped member comprises an opening at one end thereof, a perforated wall at an opposite end and first side wall extending therebetween;
- said second cup-shaped member having an opening at one end and a bottom wall at an opposite end and a second side wall therebetween; and wherein
- the two members being combined such that (i) the opening of the first member constitutes said opening of the cartridge, (ii) the perforated wall constitutes the perforated wall element of the cartridge, (iii) the bottom wall of the second member constitutes said end wall of the cartridge, and (iv) the first side wall and the second side wall jointly defining said side wall of the cartridge.
- 3. A cartridge for producing a beverage comprising
- a housing having an opening at one end sealed by a closure, an end wall at the other end and a side wall extending therebetween and generally converging from said opening to said end wall;
- a rigid perforated dividing wall element within the housing, dividing the housing's interior into a first chamber and second chamber, the first chamber is defined between said one end and said perforated element and contains dry beverage medium, and the second chamber is defined between said perforated dividing member and said end wall, the perforated dividing wall comprises holes that are dimensioned to permit passage of liquid and block passage therethrough of said dry beverage medium; and
- the housing comprises first and second cup-shaped members connected to one another, wherein said first cup-shaped member comprises an opening at one end thereof, a perforated wall at an opposite end and first side wall extending therebetween, and said second cup-shaped member having an opening at one end and a bottom wall at an opposite end and a second side wall therebetween, and wherein
- the two members are combined such that (i) the opening of the first member constitutes said opening of the cartridge, (ii) said perforated wall constitutes said dividing member of the cartridge, (iii) the bottom wall of the second member constitutes said end wall of the cartridge, and (iv) the first side wall and the second side wall jointly defining said side wall of the cartridge.
- 4. The cartridge of embodiment 2 or 3, wherein the two members are joined to one another by fitting a portion of an inner face of the second side wall adjacent the second member's opening over a bottom portion of an outer face of the first side wall adjacent the perforated wall element and tightly joining the two portions to one another.
- 5. The cartridge of any one of embodiments 2-4, wherein the two members are joined with one another by one or more of pressure-fitting, snap-fitting, embossing, screwing, welding and gluing.
- 6. The cartridge of any one of embodiment 2-5, comprising a sealing material added before joining between said portion of the inner face and said portion of the outer face.
- 7. The cartridge of any one of embodiments 1-6, wherein the perforated wall element is substantially parallel to said closure.
- 8. The cartridge of any one of embodiments 1-7, wherein the perforated dividing wall element is integral with the housing or an element thereof.
- 9. The cartridge of any one of embodiment 1-7, wherein the perforated wall element is formed by a perforated insertable element that is configured to be received within the housing's interior to divide it into said first chamber and said second chamber.
- 10. The cartridge of embodiment 9, wherein said insert is fitted into position by attaching it to or seating it on projections or shoulder formed within the cartridge's interior.
- 11. The cartridge of embodiment 10, wherein the side wall a cross-section defining a converging line extending from the opening to the end wall.
- 12. The cartridge of any one of embodiments 9-11, wherein the housing comprises first and second cup-shaped members connected to one another at respective first and second connecting ends, one or both of the first and second connecting ends having an inward-directed fold that defines said shoulder.
- 13. The cartridge of embodiment 10, wherein said insert comprises a feature that is configured to tightly engage with a counterpart form-fitting feature in the cartridge's interior to secure it in position within the cartridge.
- 14. The cartridge of embodiment 13, wherein the tight engagement is a snap-engagement.
- 15. The cartridge of any one of embodiments 1-14, configured for fitting within a cartridge-receptacle of a beverage producing machine, the closure being pierceable by a probe of said machine for introducing a liquid and the end wall being configured for engagement with an outlet arrangement of said machine for extracting the beverage from the cartridge.
- 16. The cartridge of embodiment 15, wherein the end wall is pierceable by a tubular outlet probe of said machine.
- 17. The cartridge of any one of embodiments 1-16, wherein the housing has a rounded cross-section.
- 18. The cartridge of any one of embodiments 1-17, comprising a peripheral lip surrounding the opening at said one end.
- 19. The cartridge of any one of embodiments 1-18, wherein the holes of the perforated wall element have an opening at one face thereof that has smaller dimensions than the opening at the opposite face.
- 20. The cartridge of embodiment 19, wherein the holes have a general shape of a truncated cone.
- 21. The cartridge of any one of embodiments 1-20, being a single serve cartridge for receiving a defined volume of water through the inlet probe for extracting a volume of a beverage through the outlet probe.
- 22. The cartridge of any one of embodiments 1-21, for use in preparing a beverage.
- 23. The cartridge of any one of embodiments 1-22, wherein the number and dimensions of the holes in the perforated wall element are configured to permit passage therethrough of the beverage produced in the first chamber at a rate such that the liquid introduced through the inlet probe will partially and transiently accumulate in the first chamber to properly wet the dry beverage medium.
- 24. An empty cartridge, comprising:
- a generally cup-shaped housing defined between an opening at one end, an end wall at the other end and a side wall converging from said opening to end wall;
- a rigid perforated wall element within the housing dividing the housing's interior into a first chamber and a second chamber, the first chamber is defined between said one end and said wall element and a second chamber defined between said wall element and said end wall, the perforated dividing wall element comprises holes that are dimensioned to permit passage of liquid and block passage therethrough of a dry beverage medium;
- the empty cartridge being configured for further processing that comprises introducing the dry beverage medium into said first chamber, and after said receiving sealing said opening with a closure.
- 25. The empty cartridge of embodiment 24, wherein
- the housing comprises first and second cup-shaped members connected to one another;
- said first cup-shaped member comprises an opening at one end thereof, a perforated wall at an opposite end and first side wall extending therebetween;
- said second cup-shaped member having an opening at one end and a bottom wall at an opposite end and a second side wall therebetween; and wherein
- the two members being combined such that (i) the opening of the first member constitutes said opening of the cartridge, (ii) the perforated wall constitutes the perforated wall element of the cartridge, (iii) the bottom wall of the second member constitutes said end wall of the cartridge, and (iv) the first side wall and the second side wall jointly defining said side wall of the cartridge.
- 26. An empty cartridge, comprising:
- a housing having an opening at one end sealed by a closure, an end wall at the other end and a side wall extending therebetween and generally converging from said opening to said end wall;
- a rigid perforated dividing wall element within the housing, dividing the housing's interior into a first chamber and second chamber, the first chamber is defined between said one end and said perforated element and contains dry beverage medium, and the second chamber is defined between said perforated dividing member and said end wall, the perforated dividing wall comprises holes that are dimensioned to permit passage of liquid and block passage therethrough of said dry beverage medium; and
- the housing comprises first and second cup-shaped members connected to one another, wherein
- said first cup-shaped member comprises an opening at one end thereof, a perforated wall at an opposite end and first side wall extending therebetween, and said second cup-shaped member having an opening at one end and a bottom wall at an opposite end and a second side wall therebetween, and wherein
- the two members are combined such that (i) the opening of the first member constitutes said opening of the cartridge, (ii) said perforated wall constitutes said dividing member of the cartridge, (iii) the bottom wall of the second member constitutes said end wall of the cartridge, and (iv) the first side wall and the second side wall jointly defining said side wall of the cartridge.
- 27. The empty cartridge of embodiment 25 or 26, wherein the two members are joined to one another by fitting a portion of an inner face of the second side wall adjacent the second member's opening over a bottom portion of an outer face of the first side wall adjacent the perforated wall element and tightly joining the two portions to one another.
- 28. The empty cartridge of any one of embodiments 25-27, wherein the two members are joined with one another by one or more of pressure-fitting, snap-fitting, embossing, screwing, welding and gluing.
- 29. The empty cartridge of embodiment 27 or 28, comprising a lubricant added before joining between said portion of the inner face and said portion of the outer face.
- 30. The empty cartridge of any one of embodiments 24-29, wherein the perforated wall element is substantially parallel to a plain defined by rims of said opening.
- 31. The empty cartridge of any one of embodiments 24-30, wherein the perforated dividing unit is integral with the cup-shaped housing.
- 32. The empty cartridge of any one of embodiments 24-31, wherein the perforated wall element is formed by a perforated insertable element that is configured to be received within the housing in to thereby divide the housing's interior into said first chamber and said second chamber.
- 33. The empty cartridge of embodiment 32, wherein said insertable element is fitted into position by attaching it to one or more inwardly projecting support features formed within the cartridge's interior.
- 34. The empty cartridge of embodiment 33, wherein the housing comprises first and second cup-shaped members connected to one another at respective first and second connecting ends, one or both of the first and second connecting ends having an inwardly projecting radial lip that defines the support feature.
- 35. The empty cartridge of embodiment 32, wherein said insert comprises a feature that is configured to tightly engage with a counterpart form-fitting feature in the cartridge's interior to secure it in position within the cartridge.
- 36 The empty cartridge of embodiment 35, wherein the tight engagement is a snap-engagement.
- 37. The empty cartridge of embodiment of embodiment 33, wherein the one or more support features comprises a plurality of radially symmetrically distributed inward projections.
- 38. The empty cartridge of any one of embodiments 24-37, for use in the production of a cartridge of any one of embodiments 1-23.
- 39. A cup-shaped member configured for combining with another cup-shaped member to produce the empty cartridge of any one of any one of embodiments 24-38.
- 40. A first cup shaped member, comprising:
- a first opening at its one end and a perforated wall element with holes that are dimensioned to permit passage of liquid and block passage therethrough of a dry beverage medium at its opposite end and a first side wall extending therebetween, said first member being configured for combining with a second cup-shaped member that comprises a second opening at its one end, a bottom wall at its other end and a second side wall extending therebetween, to form an empty cartridge that
- has a generally cup-shaped housing defined between said first opening at its one end and said bottom wall at its other end and a side wall between the two ends defined by the first and second side walls, and having a perforated wall within said housing constituted by said perforated wall, the perforated wall dividing the housing's interior into a first chamber defined by said first cup-shaped member and a second chamber defined by said second cup-shaped member, and that
- is configured for further processing that comprises receiving dry beverage medium into said first chamber, and after said receiving sealing said first opening with a closure, and for fitting within a cartridge-receptacle of a beverage producing machine, wherein said closure is pierceable by a tubular inlet probe for introducing a liquid and the end wall being configured for engagement with a beverage extraction arrangement of the machine for extracting the beverage from the cartridge.
- 41. The first cup-shaped member of embodiment 40, wherein said perforated wall element is substantially parallel to a plane defined by rim of said first opening.
- 42. The first cup-shaped member of embodiment 40, for producing an empty cartridge of any one of embodiments 19 to 31.
- 43. A second cup-shaped member that comprises:
- a second opening at its one end, an end wall at its other end and a second side wall extending therebetween, said second member being configured for combining with a first cup-shaped member that comprises a first opening at its one end and a perforated wall element with holes that are dimensioned to permit passage of liquid and block passage therethrough of a dry beverage medium at its opposite end, and a first side wall extending therebetween, to form an empty cartridge that
- has a generally cup-shaped housing defined between said first opening at its one end and said bottom wall at its other end and a side wall between the two ends defined by the first and second side walls, and having a dividing wall within said housing constituted by said perforated wall element, dividing the housing's interior into a first chamber defined by said first cup-shaped member and a second chamber defined by said second cup-shaped member, and that
- is configured for further processing that comprises receiving dry beverage medium into said first chamber, and after said receiving sealing said opening with a closure, and for fitting within a cartridge-receptacle of a beverage producing machine, wherein said closure is pierceable by a tubular inlet probe for introducing a liquid and the bottom wall being configured for engagement with a beverage extraction arrangement of the machine for extracting the beverage from the cartridge.
- 44. A process, comprising:
- producing a first cup-shaped member with a first opening at its one end, a perforated wall at its opposite end and a first side wall extending therebetween and converging from said first opening to said perforated wall;
- producing a second cup-shaped member with a second opening at its one end, a bottom wall at its other end and a second side wall extending therebetween and converging from said second opening to said bottom wall, said second opening being dimensioned such that internal portion of the second side wall adjacent said second opening fit snugly over an external portion of said first side wall adjacent the perforated wall;
- fitting said internal portion over said external portion; and
- joining said internal portion to said external portion, to thereby produce an empty cartridge that is configured for further processing that comprises introducing the dry beverage medium into said first chamber, and after said receiving sealing said opening with a closure.
- 45. The process of embodiment 44, wherein producing the first cup-shaped member comprises perforating holes through a first bottom wall in said first member opposite said first opening to thereby form said perforated wall.
- 46. The process of embodiment 45, comprising
- bringing a receiving surface of a first element of a puncturing apparatus into contact with one face the wall that is opposite said first member, the receiving surface comprising a plurality of cavities;
- displacing a pinned surface of a second element of said apparatus towards the opposite face of said wall, the pinned surface comprising a plurality of tapered pins projecting towards the receiving surface, each such pin being opposite one of the cavities in said receiving surface, the cavities being configured to receive at least the pin's tip therein, whereupon a plurality of holes are punched through said wall; and
- separating the first and second elements from said barrier.
- 47. The process of embodiment 46, wherein
- each of said pins has a tapered tip, whereby
- the punched holes have a dimension that is narrower at said one face than at the opposite face.
- 48. A process, comprising:
- producing an empty cartridge having a generally cup-shaped housing defined between an opening at one end, an end wall at the other end and a side wall converging from said opening to end wall, the cup-shaped housing that is configured for fitting within a cartridge-receptacle of a beverage producing machine;
- introducing a perforated wall element insert, that comprises holes that are dimensioned to permit passage of liquid and block passage therethrough of a dry beverage medium, into the housing and fitting it within the housing's interior to divide the housing's interior into a first chamber and second chamber, the first chamber is defined between said one end and said wall element, and the second chamber is defined between said wall element and said end wall, the perforated dividing wall element.
- 49. The process of any one of embodiments 44-48, for producing the empty cartridge of any one of embodiments 25-38.
- 50. The process of any one of embodiments 44-48, comprising:
- introducing dry beverage medium into said first chamber, and
- sealing said opening with a closure.
- 51. A process for the manufacture of a cartridge for producing a beverage, comprising
- introducing dry beverage medium into said first chamber of an empty cartridge of any one of embodiments 24-38, and
- sealing said opening with a closure.
- 52. The process of embodiment 50 or 52, for producing a cartridge of any one of embodiments 1-23.
BRIEF DESCRIPTION OF THE DRAWINGS
In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying schematic drawings, in which:
FIGS. 1A-1F are, respective, side view, top perspective view, longitudinal cross-sectional view, perspective cross-sectional view, bottom perspective view and a top view of an empty cartridge according to an embodiment of this disclosure in which the perforated wall element is integrally formed with the first member of the constituting members of the cartridge and where the two members are tightly joined through an embossing procedure.
FIG. 1G-1H are cross-sectional views of a cartridge of another embodiment of this disclosure in which the two members are joined together through a snap-type engagement, where FIG. 1G is an overall view of the cartridge and FIG. 1H is an enlarged view of the circled region of FIG. 1G.
FIGS. 2A-2H are longitudinal cross-sectional views (FIGS. 2A-2E, of which FIGS. 2A-2C are exploded views) and isometric cross-sectional views (FIGS. 2F-2H) of different exemplary empty cartridges with an insertable perforated wall element according to embodiments of this disclosure.
FIGS. 2I-2L are longitudinal cross-sectional views of other embodiments with an insertable perforated wall element with a form-fitting arrangement without any specific structure within the cartridge to support the proper positioning of the element; wherein FIGS. 21 and 2K are exploded views of the empty cartridge seen in respective FIGS. 2J and 2L.
FIG. 3 is a longitudinal cross-section through a cartridge for preparing a beverage according to an embodiment of this disclosure.
FIG. 4 is a schematic flow chart of a process for preparing an empty cartridge and a subsequent preparation of filled cartridge of this disclosure.
FIG. 5A and FIG. 5B are schematic production scheme for the manufacture of the two members produced from a metal foil, such as aluminum, that are subsequently combined to form the empty cartridge.
FIG. 6 is a schematic perspective view of the apparatus for joining the two members into an empty cartridge of this disclosure.
FIGS. 7A-7C are schematic cross-sectional views through the joining unit for joining the first and second members to one another in several operational stages.
FIGS. 8A-8F are schematic perspective views of the joining unit of the apparatus of FIG. 5 in 6 successive operational steps.
FIG. 9 is another alternative schematic production scheme for the manufacture of the two members, cast from a thermoplastic material such recycled or recyclable plastic, that are subsequently combined to form the empty cartridge.
DETAILED DESCRIPTION OF EMBODIMENTS
The current disclosure will now be further explained in a description of some specific, non-limiting embodiment, with reference to the annexed drawings.
Referring first to FIGS. 1A-1F, that schematically illustrate different views of an empty cartridge generally designated 100 according to an embodiment of the present disclosure. The empty cartridge 100 has a generally truncated cone shaped housing 102 defined between an opening 104 at one end and an end/bottom wall 106 at the other end and a side wall 108 extending between the two ends and generally converging from the opening 104 to the narrower bottom wall 106. The housing is constituted by two members, a first, cup-shaped member 107 (also referred to herein and “first member”) and a second, cup-shaped member 109 (also referred to herein and “second member”) that are joined together at 111 by means of embossed clinches 140. It should be noted that pressure joining, including embossing, may have various forms in which it may be applied. Additionally, rather than pressure joining the two parts may be joined by welding, gluing, or any other type of attachment that will firmly join the two parts to one another. Disposed within the housing 102 is an integral, perforated dividing wall element 110, integrally formed as a bottom perforated wall of first member 107. The perforated dividing wall element 110, in this embodiment and also in the other embodiments described below, is parallel to a plain define by rims of opening 104 but, in other embodiments, including modifications of those specifically exemplified and illustrated herein, can also have a general orientation other than parallel. Additionally, the perforated wall element may, in other embodiments, including modifications of those specifically exemplified and illustrated herein, be other than planar, e.g. curved, dome-shaped (with domed portion pointing upwards or downwards), etc. The domed portion has holes, which may be all of the same diameter, may have holes of different diameters (e.g. part having one diameter and other part another), may be arranged in different 2D arrays, etc.
The perforated dividing wall element 110 divides the housing's interior into a first chamber 112 defined between the opening 104 and the perforated dividing wall element 110 and a second chamber 114 defined between said perforated dividing wall element 110 and bottom wall 106.
In the non-limiting example of FIGS. 1A-1F, and as already noted above, the cartridge's housing 102 is made of a first cup-shaped member 107 and second cup-shaped member 109 that are attached to one another at 111. First member 107 has an opening 104 at its one end, the perforated dividing wall element 110 at its opposite end and a first side wall 130 extending therebetween. The second member 109 includes the bottom wall 106 and second side wall 132 extending upwards from the bottom wall 106 to a second opening 113. The two cup-shaped members are combined such that portion of the inner faces 136 of second wall 132 of the second cup-shaped member 109 adjacent the second opening 113 is fitted over external portions 134 of first wall 130 adjacent perforated wall element 110 of the first cup-shaped member 109 to form the empty cartridge 100, with the first and second side walls 130 and 132 jointly defining the continuous side wall 108 of the cartridge. The joining may be by in a variety of different ways, as noted above. In this embodiment, the tight joining is through embossing with the formation of a plurality of round embossed clinches 140.
Reference is now made to FIGS. 1G-1H, illustrating a different manner of joining the first and the second cup-shaped members for forming empty cartridge 100A. In these Figs. like elements to those of FIGS. 1A-IF were given like reference numerals, while those which differ from those of FIGS. 1A-1F were given like reference numeral with an added “A” (for example, first member 107A). The main difference in the exemplary embodiment of FIGS. 1G-1H from that of FIGS. 1A-1F is in the manner of joining the first member 107A and second member 107B, which is through a form-fitting engagement, whereupon the two members are snap-engaged with one another at 111A shown also in an enlarged cross-sectional view in FIG. 1H. The snap-engagement arrangement is constituted, in some embodiments as this exemplified one, by an inner circumferential protrusion 302 at an end portion 134p of the second side wall 132A and an outer circumferential groove 304 formed on the first side wall 130A. The outer circumferential groove 304 is configured for receiving the inner circumferential protrusion 302 to, thereby, tightly attach the first and second members. Empty cartridge 100A also includes structurally reinforcing ribs 306, which may or may not be included in empty cartridges or cartridges of this disclosure.
In some embodiments, the perforated dividing wall element 110 can be configured as an independent insertable element adapted to be received and held inside the housing 102. Reference is made to FIGS. 2A to 2G schematically illustrating empty cartridges according to five different exemplary embodiments, including 400 (FIG. 2A), 400A (FIG. 2B), 400B (FIG. 2C), 400C (FIGS. 2D-2F) and 400D (FIGS. 2G-2H), that are configured for receiving respective insertable perforated wall element 410, 410A, 410B, 410C and 410D and securing it in position thereinside.
In FIG. 2A, like elements (namely, elements that save a similar function) to those of FIGS. 1A-1F, were given like reference numerals shifted by 300. Thus, for example, the empty cartridge is designated 100 in FIGS. 1A-1F and 400 in FIG. 2A; the first and second cup-shaped members are respectively designated 107 and 109 in FIGS. 1A-1F and 407 and 409 in FIG. 2A; etc. Additionally, elements of empty cartridge 400A, 400B, 400C or 400D will be designated by the same reference numeral with the addition of the designation A, B, C or D. Thus, for example, the perforated wall insert is designated 110 in FIGS. 1A-IF are designated 410A, 410B, 410C and 410D in the case of, respective, empty cartridge 400A, 400B, 400C and 400D. That reader can also refer to the description of previous Figs. for understanding of the nature and function.
In the non-limiting example of FIG. 2A, the cartridge's housing 402 is made of first and second members 407 and 409 that are joined to one another at 411 via inward lips 440 formed at a bottom opening 442 of first member 407 and inwards lips 444 formed at second opening 413 of second member 409, that are tightly attached to one another, for example by gluing or welding, forming together a seat 446 for receiving and supporting the perforated wall insert 410. The insert 410 can be inserted through opening 404 and can be fixed to the seat 446, for example by gluing or welding. One insert 410 is so seated, an empty cartridge with a first chamber 412 and a second chamber 414.
In some embodiments, the insertable perforated wall element 410 has a generally planar circular or oval shape configuration conforming the cross-sectional shape of the cartridge's housing 402. The insertable perforated wall element 410 can also be non-planer, may be dome-shaped, etc.
Reference is now made to FIG. 2B which is a partial cross-section of an exploded view of an empty cartridge 400A. Like in the case of empty cartridge 400 (FIG. 2A), the first member 407A has a bottom opening 442A with inward lips 440A defining a seat for 446A. Perforated wall insert 410A has arcuated rims 448 that have a form that matches that of the seat and can thereby by be tightly attached to the seat, e.g. by welding or gluing. The second member 409A may be attached to the first member 407A in a manner similar to that of the embodiment of FIGS. 1A-1F or FIGS. 1G-1H.
Empty cartridge 400B is, in the exemplary embodiment shown in FIG. 2C, is formed from a single cup-shaped housing 402B defined between opening 404B, bottom wall 406B and side wall 408B. Formed within housing 402B are vertical ribs 448 (e.g., in a radially symmetrically arrangement) with upper ends 447 that jointly define a seat, represented by dashed line 449, for the perforated wall insert 410B.
Empty cartridge 400C in the exemplary embodiment shown in FIGS. 2D-2F, similarly to that shown in FIG. 2C, is formed from a single cup-shaped housing 402C defined between opening 404C, bottom wall 406C and side wall 408C. Formed within the housing 402C is a circumferential groove 433, best seen in FIGS. 2E-2F. Perforated wall insert 410C is formed with and upwardly projected skirt 435 that has an outwardly-directed circumferential projection 437 that matches the shape of groove 433. Consequently, once inserted into the housing 402C through opening 404C that insert 410C becomes snap-engaged and fixed within the housing.
Empty cartridge 400D in the exemplary embodiment shown in FIGS. 2G-2H, similarly to that shown in FIG. 2G-2H, is formed from a single cup-shaped housing 402D defined between opening 404D, bottom wall 406D and side wall 408D. Formed within the housing 402D is a narrow shoulder 462. Perforated wall insert 410D is formed with and upwardly projected skirt 441 that has an outwardly-directed circumferential lip 443. The skirt 441 with the lip 443 matches the form at the wall region 445 and this form-fitting arrangement secures the insert 110D in position as seen in in these Figs.
Other embodiments with an insertable perforated wall element are shown in FIGS. 2I-2L with a form-fitting arrangement without any specific structure within the empty cartridge to support the proper positioning of the element. Referring first to FIGS. 2I-2J, insert 410E has an upward projecting skirt 463 that diverges from its bases at an angle that matches that of the cone-shaped housing 402E of the empty cartridge 400E. When inserted, the insert 410E can be displaced up to a point in which it form-fits the internal surface portion of the side wall 408E, as seen in FIG. 2J. Turning now to FIGS. 2K-2L, skirt 465 has an opposite, downward converging orientation that matches that of the cone-shaped housing 402F of the empty cartridge 400F. When fully inserted, as seen in FIG. 2Lr, the skirt form-fits that of wall 408F and is arrested in this position. In the specific shown embodiment the length of the skirt 465 is such that when fully inserted, the edges thereof bear against the end wall 406F. However, in other embodiments the skirt may be shorted and its ends, once fully inserted, may be clear from the end wall.
As schematically illustrated in FIG. 3, the empty cartridge is configured for further processing in which a dry beverage medium 118 is added to the first chamber 112 and then sealing the opening 104 with a closure 120, typically an aluminum foil, as schematically illustrated in FIG. 3 to thereby obtain a cartridge 121 for preparing a beverage. The empty cartridges 100, 100A, 400, 400A, 400B, 400C and 400D may all serve for the production of a cartridge, such as cartridge 121 that is configured for fitting within a cartridge-receptacle of a beverage producing machine (not shown), such as the machine disclosed in WO 2002/080742 and WO 2002/080743 as well as in a variety of coffee makers such as those marketed by Keurig Dr. Pepper, Inc., USA (including K-Supreme®, K-Cafe®, K-Elite® and a variety of others). Closure 120 and said end wall 106 are pierceable by a tubular inlet probe of such machines for introducing a liquid and by a tubular outlet probe of said machine for extracting the beverage from the cartridge, respectively.
The end wall 106 has an embossed star-like pattern 122, with a central portion 124, providing overall structural reinforcement, with the central portion 124, being the portion, through which said outlet probe can pierce the bottom wall. It should be appreciated that the star-like central pattern 122 is an example and the central pattern may or may not be present in the end wall 106 or the pattern may have another ornamental configuration.
In the following description, unless specifically stated, the term “cartridge” will be used to denote both an empty cartridge and one in which the first chamber contains a dry beverage medium, and the opening is sealed by a closure.
The cartridges of FIGS. 1A-1H and FIG. 3 have a peripheral skirt 126 with curled periphery 128 surrounding the opening that has the primary function of forming a liquid type seal with said machine and for aiding in cartridge extraction from the machine. Also, all the illustrated cartridges have a cup-shaped housing with a rounded, particularly circular cross-section and has an overall shape of truncated cone. It should, however, be noted, that such a shape is an example and cartridges (including empty cartridges) embodying the teaching of this disclosure may also have a variety of other cross-sectional shapes such as polygonal. Also, it should be noted that the generally converging shape of the housing is an example and in other embodiments the opening and the end wall may have substantially the same dimensions.
The cartridge 121 is typically a single serve cartridge for receiving a defined volume of water through the inlet probe for extracting a volume of a beverage through the outlet probe.
The manner of producing cartridges according to a non-limiting embodiment of this disclosure is shown schematically in FIG. 4. In the manufacturing process of this embodiment 4 assemblies are used: a manufacturing line 150, 650 for producing the first member of the cartridge, a separate manufacturing line 152, 652 for producing the second member of the cartridge, both members are stacked, by a stacking arrangement for the first member 153, 653 and one for the second member 155, 655 and the stacks of the two members are then introduced into a joining apparatus 154, 654 for joining the two members to form the empty cartridge. The empty cartridge is subsequently transported to a filing station 156, 656, in which dry beverage medium is introduced into the first chamber which is then sealed with a closure (not shown) to thereby produce a filled cartridge. The manufacturing assembly schematically illustrated in FIG. 4 with its different stages 182-190 is used for the production of a metal-based cartridge, typically aluminum-based cartridge, as further described in FIGS. 5A-8F; and with its different stages 682-690 for the production of a thermoplastic-based cartridge, typically of recyclable or recycled plastic, as further described in FIG. 9.
An embodiment of the manufacturing process for each the two members, produced in this example from a metal, typically aluminum foil, can further be seen in FIGS. 5A and 5B. Turning first to the manufacture of the first members in line 150, in a first stage 160 cup-shaped devices 162, shown also in an enlarged perspective, cross-sectional view 162A and a partial further enlarged cross-sectional view 162B, are formed by a deep drawing process from a metal plate 164; and then in a next stage 165, the upright end 162C of the device's skirt is subjected to a curling process to yield a cup-shaped device 166, shown also in an enlarged, cross-sectional view 166A and a partial further enlarged cross-sectional view 166B.
In a subsequent stage 168, holes are punctured in the end wall of the device (that will eventually form the perforated dividing wall element of the cartridge) to produce a first member 170, shown also in an enlarged, perspective, cross-sectional view 170A. As can be seen, first member 170, 170A, has an end wall 172, that will constitute the perforated dividing wall element of the cartridge, that is perforated by a plurality of holes.
In order to perforate wall 172, a receiving surface of first element of a puncturing unit that has a plurality of cavities (which may be in the form of depressions, holes, etc.), of which a representative portion 174 with one cavity 176 is schematically represented in an enlarged view above member 170A, is brought into contact with one of the faces of end wall/perforated dividing wall element 172 (a portion of which 172A is seen in the enlarged view), in this case the external face (although it may also be the opposite face by other embodiments). Then a pinned surface of a second member of said unit that has a plurality of pins projecting towards the receiving surface, of which a representative pin 178 that has a tapered end 180 is shown in the enlarged view, is displaced towards the receiving surface from the opposite face of wall 172. Each of the pins is opposite one of the cavities in the receiving surface, and each such cavity is configured to receive the tapered end of the pin. The pins pierce the wall 172 to perforate it with a plurality of holes such as hole 182 seen in the enlarged view. The tapered nature of the pin means that through control of the extent of penetration of the pins through the perforated dividing wall element, the dimensions of the holes may be controlled.
The next stage 190 of the manufacturing process involves an automatic optical inspection using a camera, schematically represented at 192 and then the produced first members are stacked into stacks 194 of such members.
The manufacture second cup-shaped members 202, of which a perspective cross-sectional view is blown up at 202A, is produce in a one-step deep drawing stage 204. The second cup-shaped members 202 pass through an automatic optical inspection using a camera, schematically represented at 206 and then the said second members are stacked into stacks 208 of such members. The second cup-shaped members are designed to have an opening that is dimensioned such to fit over said perforated dividing wall element as noted above.
The stacks 194 and 208 may then be transported to apparatus 154 that is seen in a schematic perspective view in FIG. 6. Apparatus 154, in this embodiment, has 3 parallel processing lines 210, which are functionally identical to one another. It should be noted that in other embodiments such an apparatus may comprise only one or a different number of such processing lines.
Each line 210 includes two feeding lanes, including a first feeding lane 212 for feeding the first members 170 from a stack of such members 194, and including second feeding lane 214 for feeding the second members 202 from a stack of such members 208. As can be seen, feeding lane 212 is at a lower level than feeding lane 214. At the end of the feeding lines, each second member 202 is stacked onto a first member 170 and these two stacked members are then fed into the joining unit 216, in which, through an embossing process, the two members are joined to one another in an embossing process, to be described below, to produce cartridges 100. The cartridges 100 are then displaced along a cartridge feeding line 220. These empty cartridges may be collected at the end of the line or may be fed directly into a feeling station, in which each cartridges receives a dry beverage medium into its first chamber and the cartridge's opening is then sealed by a closure. For that purpose, the cartridges are turned by 180 degrees at 222, for example through the use of guiding rails, and the turned cartridges are then transported into the filling station.
By some embodiments, Line 210 may also include a hole-puncturing unit 224 instead of such unit in first members manufacturing line 150. Additionally, each of lines 210 may also include a lubrication unit for applying a lubricant on external surface portions of first members 170 and/or internal surface portions of second member 202, to ensure a gas-tight seal between joined portion of these two members.
Referring now to FIGS. 7A-7C, showing perspective longitudinal cross-sections through part of joining unit 216 (shown in FIG. 5) in three operational steps. Once the stack of first member 170 and second member 202 is introduced into the joining unit, as seen in FIG. 7A, a cylindrical press 225 is pressed downwards in the direction of arrow 226 whereby portion 134 of second member 202 is snugly fitted about portion 136 of first member 170. At a subsequent step, seen in FIG. 7B, annular press 228, which has an outwardly slanted interface 230 at its bottom end, is lowered as represented by arrow 232. External embossing elements 234 have a corresponding slanted face 236 and consequently downward displacement of press 228 causes an inward radial displacement of elements 234 as represented by arrow 235. Internal embossing elements 240 are radially externally displaced, in the direction represented by arrows 244, by an upward displacement of coned press 242, as represented by arrow 246. This opposite relative radial displacement of elements 234 and 240 induces an embossing-based joining of portions 134 and 136 to one another. As can be seen in FIG. 7C, the entire upper portion of the unit is then upwardly displaced leading to the external radial displacement of elements 234 and upward displacement of extraction cylinder 238, as represented by arrow 248, causes upward lifting of the form cartridge 100 which can then be removed from unit 216.
Referring now to FIGS. 8A-8F, showing successive steps in the joining process. In FIG. 8A, a two-member stack 250 consisting of a second member 202 on top of a first member 170, is introduced into joining unit 216 that has a top assembly 252 and a bottom assembly 254. Assembly 252 is then lowered, as represented by arrow 256 is FIG. 8B, and one fully lowered the engagement of the bottom end of the cylindrical press 225 with the end wall of member 202 until it finally encloses stack 250, as seen in FIG. 8C. Cylindrical press 225 is lowered, as seen in FIG. 8D, to press onto end wall of member 202, as seen in FIG. 7A, and then following embossing, as shown in FIG. 7B, assembly 252 is lifted to exposed the formed cartridge 100, which is then laterally displaced into line 220 (see FIG. 6) by a displacer element 258 which can reciprocate along a line, as represented by arrow 260, which after laterally displacing the cartridge retracts back to its original position.
Referring now to FIG. 9, illustrating another manufacturing process for each the first and second members of the cartridge and their attachment to one another to form the cartridge. In the first stage S1, the first and second members 610 and 612 of the cartridge are manufactured in respective manufacturing lines 650 and 652 by respective devices 600A and 600B which involve a deep drawing process or casting, e.g., from a polymeric material plate 601 such as polyethylene, polypropylene, a recycled or recyclable material, biodegradable material, etc. then holes are punctured in the end wall of the device (not shown), that will eventually form the perforated dividing wall of the cartridge, to produce a first member 610, for example in a manner similar to that described in FIGS. 4A and 4B. In a subsequent stage S2, the first members are stacked together to form and array of stacks 614 in manufacturing line 653 and the second members are stacked together to form and array of stacks 616 in manufacturing line 655. The stacks 614 and 616 may then be transported, in step S3, to apparatus 620. In a subsequent stage S4, each second member is joined to a respective first member in apparatus 620 in manufacturing line 654, e.g., by a snapping engagement or any other type of engagement described above. In subsequent stage the so produced empty cartridges may be filled with a solid beverage medium and sealed, similarly as described above.
In connection to the manufacturing processes of FIGS. 8A-8F and 9, it should be noted that, the first member may be manufactured with opening at its both end (i.e., having cylindrical or truncated cone configuration) and the perforated diving element may be manufactured separately as an independent insertable element. The insertable perforated may be coupled to the first member or the second member prior to their attachment to each other or thereafter. To this end, any one of the first and second members can be manufactured with the support elements/featured described in FIGS. 2A-2B.
Patent Application
20240300730
