APPARATUS AND METHOD FOR MANUFACTURING A CAPSULE FOR INFUSION PRODUCTS

Technical field

This invention relates to an apparatus and a method for making a capsule intended to contain a product whose soluble components will be extracted by means of a fluid, particularly a pressurized fluid. This invention is applicable particularly advantageously in the coffee capsule sector.

Background art

Known in the prior art (for example, from patent documents WO2014154552, WO2015056202 and WO2014191044) are capsules comprising a cup of plastic material, filled with a dose of product (for example, coffee powder) and closed by a cover defined by a circular panel sealed onto the cup. The cup has a flat annular flange onto whose front surface the cover is sealed.

The cup and/or cover of prior art capsules may be provided with holes to allow the pressurized fluid to pass through the capsule during use in a machine for brewing the beverage (for example, a coffee machine or an infusion machine). Alternatively, the cup and/or the cover may have zones of weakness which, inside the machine for brewing the beverage, break under the action of the fluid pressure or of specific tools (also known as "knives") the machine is equipped with, so as to allow the pressurized fluid to pass through the capsule. For example, a coffee machine is typically equipped with a hood configured to clamp down on and seal the annular flange of the capsule in order to brew the coffee according to a method known in the coffee machine sector.

It should be noted that this invention refers in particular to cups and capsules designed to be opened at the bottom of the cup. In other words, this invention refers in particular to cups and capsules designed to be used in machines whose knives perforate the capsule through the bottom of the cup.

In these coffee machines, a rear surface of the annular flange is pressed, during infusion, against an upper edge of a pressure hood element in such a way as to create a fluid-tight seal between the cup and the hood on the rear surface of the annular flange, at the bottom end of the cup, where the cup is perforated by the knives.

The cup of prior art capsules may be made by moulding of polymeric material. In this case, the holes or the zones of weakness on the cup are made during the moulding of the cup by suitably shaping the polymeric material inside the mould in which the cup is being formed.

Making the holes or the zones of weakness by moulding, however, entails numerous disadvantages.

First of all, a mould which is capable of forming holes is a complex mould, difficult to make and easy to break. These disadvantages are even worse if the holes which the mould must be capable of making are just a few tenths of a millimetre in diameter. Furthermore, providing a mould which is capable of forming zones of weakness on the cup is not easy, especially if the zones of weakness are just a few hundredths of a millimetre thick. As a result, the mould is very expensive.

Moreover, making the holes or the zones of weakness by moulding means little flexibility both in the properties of the capsule and in the production process. In effect, to modify the shape and/or size of the holes or of the zones of weakness, a new mould must be provided, with all the costs that this involves. Similarly, changing the material the cup is made of means changing the design of the cup and of the mould in order to adapt them to the new material, which once again means providing a new mould.

Yet another disadvantage of the zones of weakness made by moulding is that such zones are delimited by very large fillet radiuses. In effect, to allow the fluid polymeric material to flow through narrow passages of the mould, such as those in which the zones of weakness are formed, it is necessary to adopt curvature radiuses which are greater than a limit value. These zones of weakness, however, tend to break with difficulty when they come into contact with the pressurized fluid in the machine for brewing the beverage.

Disclosure of the invention

This invention has for an aim to provide an apparatus and a method for making a capsule to overcome the above mentioned disadvantages of the prior art and to meet the above mentioned requirements.

More specifically, the aim of this invention is to provide an apparatus and a method for making a capsule which are particularly precise and flexible. A further aim of this invention is to provide an apparatus and a method for making a capsule which are particularly efficient and reliable.

These aims are fully achieved by the apparatus and method according to the invention as characterized in the appended claims.

More specifically, the apparatus for making a capsule for beverages (where the capsule has an infusion product contained in the cup and a cover for sealing the cup) comprises a thermoforming station configured to receive a multilayer sheet fed into it. The thermoforming station comprises a plurality of thermoforming units, each configured to receive a corresponding forming zone of the multilayer sheet and to blow it into a mould in order to make a corresponding pocket. Each pocket has a bottom wall and a side wall which connects the bottom wall to an annular flange located at an upper edge of the pocket. Each thermoforming unit comprises a cup-shaped mould having a main cavity to form the body of a pocket (preferably by blowing). The cup-shaped mould comprises a shaped annular portion which surrounds the main cavity and is spaced radially therefrom by a predetermined length. Preferably, each thermoforming unit comprises a hood element provided with an annular presser configured to press the multilayer sheet onto the shaped annular portion of the mould to form an underside face of the annular flange, facing the bottom wall of the pocket, imparting a profile which defines at least one annular groove and one ridge.

While the pocket is being blown into the main cavity of the cup-shaped mould, the annular flange cooperates with the shaped annular portion of the mould and with the annular presser of the hood element to create a fluid tight seal in the hood element and in the cup-shaped mould.

The apparatus according to the invention comprises a working station configured to receive the multilayer sheet defining the plurality of pockets. The working station has a plurality of working units, each equipped with a work tool having an operating end. Each work tool is movable along a working direction from a position of non-interference with the respective pocket to an operating position where the operating end interacts with the bottom wall of the respective pocket in order to work it. The apparatus comprises a plurality of centring elements configured to butt up against a portion of the side wall of each pocket in order to align it with the corresponding working direction.

The apparatus comprises a cutting station configured to receive the multilayer sheet defining the plurality of worked pockets. The cutting station comprises a plurality of cutting units, each configured to separate a respective pocket from the multilayer sheet and to form a corresponding cup.

In an example embodiment, (each) working unit comprises a scoring tool (or scorer). The scorer has a shaped operating end (comprising, for example, a plurality of protrusions) to score the bottom wall of the respective pocket. Preferably, the scorer is movable between a position of non-interference with the pocket and an operating position where it cuts an inner layer of the bottom wall of the cup. Still more preferably, in the operating position, the scorer cuts only a first layer (that is, an inner layer) of the bottom wall of the cup.

In a further example embodiment (each) working unit comprises a punch configured to cut at least one through hole in the bottom wall of the respective pocket.

Further, in the context of a plurality of working stations, some stations might be equipped with a scorer to cut a (pre-)score mark on corresponding pockets, while other stations might have a punch to cut through holes in further and different corresponding pockets.

In an example embodiment, the apparatus comprises a first movement element for the multilayer sheet, configured to move the multilayer sheet in a feed direction and located between the thermoforming station and the working station.

Preferably, the first movement element is configured to feed the multilayer sheet in the feed direction until reaching at least one predetermined operating position (corresponding to a respective station of the apparatus) and to stop the multilayer sheet at the at least one operating position for a predetermined length of time (necessary to perform the operations the corresponding station is designed for).

In an example embodiment, the cutting station is located downstream of the working station. The apparatus comprises a filling station configured to place a plurality of doses of infusion product (for example, coffee) into a plurality of cups (previously separated from the multilayer sheet). The apparatus also comprises a sealing station configured to receive the plurality of cups and a sealing sheet. The sealing unit is configured to seal the cups by securely joining disc-shaped portions of the sealing sheet to the annular flange of each cup, thereby making the capsules.

In a further example embodiment, the cutting station is located downstream of the sealing station. The apparatus comprises a filling station configured to place a plurality of doses of infusion product (for example, coffee) into the plurality of pockets (still joined to the multilayer sheet). The sealing station is configured to receive the plurality of pockets and the sealing sheet. The sealing unit is configured to seal the pockets by securely joining disc-shaped portions of the sealing sheet to the annular flange of each pocket. The cutting station is configured to receive the multilayer sheet defining the plurality of pockets, joined to the sealing sheet by the respective annular flanges. Each cutting unit is configured to separate a respective pocket from the multilayer sheet, thus also separating the corresponding disc-shaped portions of the sealing sheet, thereby forming the capsules by separating them directly from the multilayer sheet and from the sealing sheet.

In an example embodiment, the apparatus comprises a plurality of weakening blades configured to score or cut the multilayer sheet in one or more zones of weakness interposed between the forming zones. Preferably, the plurality of weakening blades is located upstream of the working station.

Also defined according to this description is a method for making a beverage capsule cup (where the capsule has an infusion product contained in the cup and a cover for sealing the cup), comprising the following steps:

- feeding a multilayer sheet having an inner layer and an outer layer made of thermoplastic materials, and also having, between the inner and outer layers, a middle layer made of a material which is impermeable to oxygen and/or to aromas;

- heating the multilayer sheet;

- forming (also referred to, in this document, without distinction, as thermoforming) by blowing the multilayer sheet into a plurality of forming zones, so as to impart to it a three-dimensional shape defining a plurality of pockets, each having a bottom wall intended to be pierced during use of the capsule, and a side wall which connects the bottom wall to an annular flange located at an upper edge of the pocket, where the inner layer defines an inside surface of the pocket,

- working the bottom wall of the pockets by moving a work tool along a working direction intersecting the multilayer sheet;

- separating the pockets from the multilayer sheet to form corresponding cups. According to the invention, the method comprises a step of aligning each pocket of the plurality of pockets relative to the corresponding working direction. This step precedes or is simultaneous with the step of working the bottom wall.

Preferably, the step of working the bottom wall of the pockets precedes the step of separating the pockets from the multilayer sheet.

Preferably, the aligning step comprises a step of moving relative to each other the pockets of the plurality of pockets and respective centring elements of a plurality of centring elements. Each centring element is configured to butt up against at least one portion of the side wall of each pocket.

In an example embodiment, each centring element is configured to abut against at least one portion of a side wall of the pocket from the outside. For example, the working unit comprises a plurality of hollow elements (or cavities) having a frusto-conical cross section. Each cavity is provided with a bottom wall, preferably flat, configured to butt up against the bottom wall of the respective pocket, and with an inclined side wall to butt up against at least one portion of the side wall of the respective pocket. In a further example embodiment, the centring element is a ring of predetermined diameter configured to butt up against a portion of the side wall of the respective pocket at a predetermined height. Preferably, the method comprises a step of positioning the pockets of the plurality of pockets inside respective centring elements configured to butt up against at least one portion of the side wall of each pocket from the outside.

In a further example embodiment, the centring element is configured to butt up against at least one portion of the side wall of the pocket from the inside. For example, the centring element is a shaped plate having an annular protrusion of predetermined diameter configured to butt up against at least one portion of the side wall of the capsule from the inside, in proximity to an upper edge. Preferably, the method comprises a step of positioning the pockets of the plurality of pockets in contact with respective centring elements configured to butt up against at least one portion of the side wall of each pocket from the inside.

In an example embodiment, the working step comprises a step of scoring (or pre-scoring) a portion of the bottom wall of the pocket by means of a scoring tool, so as to define a zone of weakness.

Preferably, the score mark is made on a portion of the inside surface of the bottom wall. Still more preferably, during the scoring step, the scoring tool cuts only the inner layer of the bottom wall and does not cut the middle layer.

Preferably, the score mark penetrates to a depth greater than half the thickness of the bottom wall of the pocket.

In an example embodiment, the working step comprises a step of cutting at least one through hole in the bottom wall. The method also comprises a further step of sealing the through hole by means of a bottom cover.

Instead of scoring, the working step alternatively comprises perforating the bottom of the pocket by means of a punch (and then sealing with respective sealing elements).

In this context, it should be noted that working by scoring makes it possible to avoid the step of covering with a sealing element which, instead, is necessary in the event of working by perforating with a punch, with evident economic and logistic advantages.

In an example embodiment, the method comprises a step of stamping the annular flange located at the upper edge of each pocket so as to shape an underside face of the annular flange facing the bottom wall of the pocket to impart to it a profile defining at least one annular groove and one annular ridge.

Preferably, stamping is performed in the thermoforming station. Preferably, the stamping step starts (just) before the thermoforming step. In effect, stamping occurs upon closing a mould composed of a cup-shaped mould (defining a first half-mould) and a hood element (defining a second half mould). When this mould is closed, a shaped annular portion of the cup- shaped mould presses the annular flange against an annular end presser of the hood element, thereby completing the stamping step.

Thermoforming, which entails moving a punch downwards (stretching step) and allowing air to enter the mould (blowing), occurs preferably after the stamping step. Preferably, during the blowing step, the mould is still closed and the annular flange (stamped or in the process of being stamped) acts in conjunction with the shaped annular portion and with the annular end presser of the hood element in order to create a seal inside the mould.

Preferably, during the stamping step, the annular flange is pressed between a shaped annular portion of a cup-shaped mould and an annular end presser of a hood element, so that while the pocket is being blown into the main cavity of the cup-shaped mould, the annular flange cooperates with the shaped annular portion of the cup-shaped mould and with the annular presser of the hood element to create a fluid tight seal in the hood element and in the cup-shaped mould.

In an example embodiment, the method comprises the following further steps:

- filling each pocket of the plurality with a dose of infusion product;

- positioning a sealing sheet on the multilayer sheet;

- sealing the pockets of the plurality by securely joining disc-shaped portions of the sealing sheet to the annular flange of the pocket.

Preferably, the step of separating the pockets from the multilayer sheet causes the corresponding disc-shaped portions of the sealing sheet to be also separated, thereby forming the corresponding covers and thus forming the capsules separated directly from the multilayer sheet and from the sealing sheet.

In an example embodiment, the method comprises a step of scoring or cutting the multilayer sheet in one or more zones of weakness of the sheet, interposed between the forming zones. Brief description of the drawings

The technical features of the invention, with reference to the above aims, are clearly described in the appended claims and its advantages are more apparent from the detailed description which follows, with reference to the accompanying drawings which illustrate a preferred, non-limiting example embodiment of it and in which

- Figure 1 is a schematic representation of the apparatus of this description;

- Figure 2 shows a variant embodiment of the apparatus of Figure 1 ;

- Figures 3 and 4 schematically show some details of a working station of the apparatus of Figure 1 ;

- Figures 5, 5A and 5B show are detail views of the scoring tool according to this description;

- Figure 6 schematically represents a working station in a perspective view;

- Figures 7, 7A, 7B, 7C and 8 show an example of a cup made using the apparatus of Figure 1.

Detailed description of preferred embodiments of the invention

With reference to the accompanying drawings, the numeral 100 denotes an apparatus for making a coffee capsule 50 according to this description. It should be noted that the term capsule 50 is used in this description to denote a container (for containing a dose 30 of an infusion product) comprising a cup 1 and a sealing cover 40 (also called sealing disc 40) intended to hermetically isolate the product dose 30.

The cup 1 comprises a containment body 2 which internally defines a space V, open at the top, for containing the dose 30 of infusion product. The containment body 2 extends between a bottom wall 2A (or bottom 2A) and an upper edge 2B. The containment body 2 comprises an annular flange 3 located at the upper edge 2B of the containment body 2.

The annular flange 3 extends around an axis X which preferably constitutes an axis of axial symmetry of the containment body 2 and, still more preferably, of the entire cup 1. The annular flange 3 lies mainly in a flat plane, perpendicular to the axis X.

The annular flange 3 has a rear (or underside) face 3A, directed towards the containment body 2, and a front (or top) face 3B, adapted to receive the sealing cover 40 applied to it in order to hermetically isolate the dose 30 of coffee inside the space V to obtain the capsule 50.

The apparatus 100 comprises a thermoforming station configured to receive a multilayer sheet 10 (preferably made of one or more thermoplastic materials) fed into it. The thermoforming station comprises a plurality of thermoforming units 200, each configured to receive a corresponding forming zone of the multilayer sheet 10 and to blow it into a cup-shaped mould 202 in order to make a corresponding pocket 12.

Each pocket has a side wall 2C which connects the bottom wall 2A to an annular flange 3 located at an upper edge 2B of the pocket 12. It should be noted that the term pocket 12 is used to denote the cup 1 before it is separated from the multilayer sheet 10.

In an example embodiment, the multilayer sheet 10 is a polymer web fed from a roll 1 . Preferably, the multilayer sheet 10 is configured to move in a feed direction L.

In an example embodiment, the multilayer sheet 10 comprises:

- an inner layer made of a plastic material, defining the front face 3B of the annular flange 3 and the inside surface of the containment body 2;

- an outer layer made of a soft plastic material whose hardness is preferably less than that of the inner layer;

- a middle layer, between the inner layer and the outer layer, made of a material impermeable to oxygen and aromas.

The inner layer is made of a material which can confer good rigidity on the bottom 2A of the containment body 2 when the bottom 2A itself is subjected to the cutting action of specific knives (not illustrated). This material is preferably polypropylene. The outer layer is made of a material which is deformable enough to allow it to adhere to a pressure hood element during brewing of the beverage. This material preferably has a hardness which is less than that of the material the first layer is made of. The outer layer is made preferably of polyethylene. Alternatively, the outer layer might be made of polypropylene or other materials.

It should be noted that the outer layer of the cup 1 (that is, of the flange 3 of the cup 1 ) is made of a soft, deformable material. This material can undergo at least partly plastic deformation. Preferably, the material the outer layer is made of can also undergo at least partly plastic deformation. In light of this, it should be noted that the elasticity modulus of the layer is preferably less than 1400 MPa (that is, the elasticity modulus of the layer is included in the interval [0, 1400] MPa). The middle layer is made preferably of EVOH or other barrier material.

In an example embodiment, the thickness of the inner layer is greater than the thickness of the outer layer. Preferably, the thickness of the inner layer is greater than the sum of the thicknesses of the outer layer and of the middle layer.

The thermoforming station comprises heating elements 201 adapted to soften the multilayer sheet 10 in order to make it plastically deformable. The heating elements 201 might, for example, be electrical resistors located on opposite sides of the multilayer sheet 10, or they might be IR ray emitters.

Each thermoforming unit 200 comprises shaping elements adapted to deform the multilayer sheet 10 to give it a three-dimensional shape defining at least one pocket 12. It should be noted that the term pocket 12 is used substantially to denote the cup 1 before it is separated from the multilayer sheet 10.

Preferably, each thermoforming unit 200 comprises a cup-shaped mould 202 and a shaping tool 203 which are movable relative to each other.

Preferably, the thermoforming station is connected to a pneumatic circuit 205, configured to supply compressed air to the thermoforming units 200 and to blow the multilayer sheet 10 to form the pockets 12.

The cup-shaped mould 202 has a main cavity 202A which has a frusto- conical cross section and which extends in a main direction P. The main cavity 202A has a bottom and a main opening which are oriented substantially perpendicularly to the main direction P. The radial extension of the main opening is greater than the radial extension of the bottom of the cup-shaped mould 202, giving the pocket 12 a substantially frusto- conical cross section.

The cup-shaped mould 202 comprises a shaped annular portion 202B which surrounds the main cavity 202A and is spaced radially therefrom by a predetermined length.

It should be noted that the main cavity 202A is functional to the forming of the containment body 2, whilst the shaped annular portion 202B is functional to the forming of the annular flange 3.

In an example embodiment, each thermoforming unit 200 comprises a hood element 204 provided with an annular presser configured to press the multilayer sheet 0 onto the shaped annular portion 202B of the cup- shaped mould 202 to form an underside face 3A of the annular flange 3, facing the bottom wall 2A of the pocket 12, imparting a profile which defines at least one annular groove 4 and one ridge 6.

In a preferred embodiment, the shaping tool 203 is movable towards and away from the bottom of the cup-shaped mould 202, so as to force a portion of the multilayer sheet 10 into the main cavity 202A of the cup- shaped mould 202 and deform it plastically, thereby forming the at least one pocket 12 by blowing (by means of compressed air).

While the pocket 12 is being blown into the main cavity 202A of the cup- shaped mould 202, the annular flange 3 cooperates with the shaped annular portion 202B of the cup-shaped mould 202 and with the annular presser of the hood element 204 to create a fluid tight seal in the hood element 204 and in the cup-shaped mould 202. The apparatus according to the invention comprises a working station configured to receive the multilayer sheet 10 defining the plurality of pockets 12. The working station comprises a plurality of working units 300. Each working unit 300 comprises at least one work tool 304 having an operating end which is configured to work the bottom wall 2A of the respective pocket 12.

Each work tool 304 is movable along a working direction W from a position of non-interference with the respective pocket 12 to an operating position where the operating end interacts with the bottom wall 2A of the respective pocket 12 in order to work it.

In an example embodiment, the working unit 300 comprises a scoring tool 301 configured to cut the bottom wall 2a of the pocket 12 from the inside. Preferably, the scoring tool 301 is configured to cut only the inner layer of the multilayer sheet 10.

In an example embodiment, the scoring tool 301 (or scorer 301 ) has a first end and a second end and extends in a longitudinal direction A. The first end is connected to a movement mechanism by which the scorer 301 is moved. Preferably, the movement mechanism of the scorer 301 is configured to move the scorer 301 along the working direction W, substantially perpendicular to the feed direction L of the multilayer sheet

10. In other words, the scorer 301 is movable between a position of noninterference with the pocket 12 and an operating position where it cuts the inner layer of the bottom wall 2a.

Preferably, the second end of the scorer 301 has a plurality of protrusions 301 A (or serrations) for scoring the bottom wall 2a. In an example embodiment, the scoring tool 301 is cylindrical in shape and the second end has a plurality of concentric, circular protrusions.

In an example embodiment, the working unit 300 comprises an abutment element 302 for the bottom wall 2a of the at least one pocket 12. The abutment element 302 has a supporting surface for the bottom wall 2a of the pocket 12 and is configured to abut against the bottom wall 2a from the outside.

In a further example embodiment, the working unit 300 comprises a punch configured to cut at least one through hole in the bottom wall 2a of the at least one pocket 12. Preferably, the apparatus comprises a bottom sealing station configured to receive a plurality of pockets 12 (or of cups 1 ) and to seal the through hole by applying a bottom cover.

The working unit 300 of the apparatus 100 according to the invention comprises a plurality of centring elements 303 configured to define a predetermined working position for the at least one pocket 12. More specifically, each centring element 303 is configured to abut against at least one portion of a side wall 3C of the pocket 12 (that is, a portion of the containment body 2 which joins the bottom 2A to the flange 3).

In other words, the centring elements 303 are configured to butt up against at least one portion of the side wall 2C of each pocket 12 in order to align it with the corresponding working direction W.

In an example embodiment, the centring element 303 is configured to butt up against at least one portion of the side wall 2C of the pocket 12 from the outside. For example, the abutment element 302 and the centring element 303 are made in a single piece. In other words, the working unit 300 comprises a hollow element (or cavity) provided with a bottom wall acting as an abutment element 302 and with inclined side walls acting as centring element 303. In a further embodiment, the centring element 303 has an annular shape and is configured to butt up against at least one portion of the side wall 2C of the pocket 2 at a predetermined height. In a further example embodiment, the centring element 303 is configured to butt up against the side wall of the pocket 12 from the inside. For example, the centring element 303 is connected to the work tool 304 to butt up against the side wall of the pocket 12 from the inside. Preferably, the work tool is movable relative to the centring element 303. That way, the work tool is able to score the bottom wall 2a (or make a through hole in the bottom wall 2a) while the pocket 12 is held in the working position by the centring element 303.

In a further embodiment, the centring element 303 is a shaped plate having an annular protrusion configured to butt up against the side wall pocket 12 from the inside, in proximity to the upper edge 2b. Preferably, the shaped plate has a through hole to allow the work tool to pass through it.

The apparatus 100 comprises a cutting station configured to receive the multilayer sheet 10 defining the plurality of worked pockets 12. The cutting station comprises a plurality of cutting units 400, each configured to separate a respective pocket 12 from the multilayer sheet 10 and to form a corresponding cup 1.

In an example embodiment, the cutting unit 400 comprises a cutting tool 401 which is movable between a position of non-interference with the multilayer sheet 10 and a working position where it cuts the multilayer sheet 10 at an outer edge 3C of the annular flange 3 in order to separate the pocket 12 from the multilayer sheet 0 to obtain a cup 1 .

In an example embodiment, the cutting station is located downstream of the working station. The apparatus comprises a filling station having a plurality of filling units 500 configured to place a dose 30 of infusion product (for example, coffee) into a respective cup 1 (previously separated from the multilayer sheet 10). The apparatus 100 also comprises a sealing station configured to receive a plurality of cups 1 and a sealing sheet 13. The sealing station comprises a plurality of sealing units 600 and is configured to seal the cups 1 by securely joining disc-shaped portions of the sealing sheet 13 to the annular flange 3 of each cup 1 , thereby making the capsules 50.

In a further example embodiment, the cutting station is located downstream of the sealing station. The filling station has a plurality of filling units 500 configured to place a dose 30 of infusion product (for example, coffee) into a respective cup 12 (still joined to the multilayer sheet 10). The sealing station is configured to receive the plurality of pockets 12 and the sealing sheet 13. Each sealing unit 600 is configured to seal the pockets 12 by securely joining disc-shaped portions of the sealing sheet 13 to the annular flange 3 of each pocket 12. The cutting station is configured to receive the multilayer sheet 10 defining the plurality of pockets 12, joined to the sealing sheet 13 by the respective annular flanges 3. Each cutting unit 400 is configured to separate a respective pocket 12 from the multilayer sheet 10, thus also separating the corresponding disc-shaped portions of the sealing sheet 13, thereby forming the capsules 50 by separating them directly from the multilayer sheet 10 and from the sealing sheet 13.

In an example embodiment, the apparatus comprises a plurality of weakening blades configured to score or cut the multilayer sheet 10 in one or more zones of weakness interposed between the forming zones. Preferably, the plurality of weakening blades is located upstream of the working station.

Each filling unit 500 comprises, for example, a doser 501 configured to place the coffee dose 30. Preferably, each sealing unit 600 comprises a sealing presser 601 (for example, a hood presser) configured to join the sealing cover 40 to at least one pocket 12 at the annular flange 3.

In an example embodiment, the apparatus 100 comprises a reel 15 for taking up the residual multilayer sheet (that is, the multilayer sheet without the pockets). Preferably, the apparatus also comprises an idler pulley 1 1A configured to divert the multilayer sheet from its feed direction L towards the take-up reel 15.

Preferably, the apparatus 100 comprises a second roll 14 to feed the sealing sheet 10 into the sealing station. Preferably, the apparatus comprises a second idler pulley 14A to vary a feed direction of the sealing sheet 13 (from the second roll 14) and make it substantially parallel to the feed direction L of the deformed multilayer sheet 10.

In an example embodiment, the apparatus comprises a first movement element configured to move the multilayer sheet 10 in a feed direction L. Preferably, the first movement element is located between the thermoforming station and the working station.

In an example embodiment, the first movement element is configured to feed the multilayer sheet until reaching at least one predetermined operating position and to stop the multilayer sheet at this operating position for a predetermined length of time.

In a further example embodiment, the apparatus comprises a second movement element, downstream of the filling station. This solution allows accumulating a portion of multilayer sheet between the thermoforming station and the working station in the case where at least a first and a second station of the apparatus are configured to operate simultaneously on a first plurality of pockets and on a second plurality of pockets, where the number of pockets in the first plurality of pockets is different from the number of pockets in the second plurality of pockets.

Also defined according to this description is a method for making a cup 1 of a beverage capsule 50 (where the capsule contains a dose 30 of an infusion product inside the cup 1 and a cover 40 for sealing the cup), comprising the following steps:

- feeding a multilayer sheet 10 having an inner layer and an outer layer made of thermoplastic materials, and also having, between the inner layer and the outer layer, a middle layer made of a material which is impermeable to oxygen and to aromas;

- heating the multilayer sheet 10;

- forming by blowing the multilayer sheet 10 into a plurality of forming zones of the sheet 10, so as to impart to it a three-dimensional shape defining a plurality of pockets 12, each having a bottom wall 2A intended to be pierced during use of the capsule 50, and a side wall 2C which connects the bottom wall 2A to an annular flange 3 located at an upper edge 2B of the pocket 12, where the inner layer defines an inside surface of the pocket 12,

- working the bottom wall 2A of the pockets 12 by moving a work tool 304 along a working direction W intersecting the multilayer sheet 10;

- separating the pockets 12 from the multilayer sheet 10 to form corresponding cups 1.

According to the invention, the method comprises a step of aligning each pocket 12 of the plurality of pockets 12 relative to the corresponding working direction W. This step precedes or is simultaneous with the step of working the bottom wall 2A.

Preferably, the step of working the bottom wall 2A of the pockets 12 precedes the step of separating the pockets 12 from the multilayer sheet 10.

Preferably, the aligning step comprises a step of moving relative to each other the pockets 12 of the plurality of pockets 12 and respective centring elements 303 of a plurality of centring elements 303. Each centring element 303 is configured to butt up against at least one portion of the side wall 2C of each pocket 12.

In an example embodiment, each centring element 303 is configured to abut against at least one portion of a side wall 2C of the pocket 12 from the outside. Preferably, the method comprises a step of positioning the pockets 12 of the plurality of pockets 12 inside respective centring elements configured to butt up against at least one portion of the side wall 2C of each pocket 12 from the outside.

In a further example embodiment, the centring element 303 is configured to butt up against at least one portion of the side wall 2C of the pocket 12 from the inside. Preferably, the method comprises a step of positioning the pockets 12 of the plurality of pockets 12 in contact with respective centring elements 303 configured to butt up against at least one portion of the side wall 2C of each pocket 12 from the inside.

In an example embodiment, the working step comprises a step of scoring a portion of the bottom wall 2A of the pocket 12, by means of a scoring tool 301 , so as to define a zone of weakness.

Preferably, the score mark is made on a portion of the inside surface of the bottom wall 2A. Still more preferably, during the scoring step, the scoring tool 301 cuts only the inner layer of the bottom wall 2A and does not cut the middle layer.

Preferably, the score mark penetrates to a depth greater than half the thickness of the bottom wall 2A of the pocket 12.

In an example embodiment, the working step comprises a step of cutting at least one through hole in the bottom wall 2A. The method also comprises a further step of sealing the through hole by means of a bottom cover.

In an example embodiment, the method comprises a step of stamping the annular flange 3 located at the upper edge 2B of each pocket 12, simultaneously or prior to the forming step (and preferably in the thermoforming station itself) so as to shape an underside face 3A of the annular flange 3 facing the bottom wall 2A of the pocket to impart to it a profile defining at least one annular groove 4 and one annular ridge 6.

Preferably, during the stamping step, the annular flange 3 is pressed between a shaped annular portion 202B of a cup-shaped mould 202 and an annular end presser of a hood element 204, so that while the pocket 12 is being blown into a main cavity 202A of the cup-shaped mould 202, the annular flange 3 cooperates with the shaped annular portion 202B of the cup-shaped mould 202 and with the annular presser of the hood element 204 to create a fluid tight seal in the hood element 204 and in the cup- shaped mould 202.

In an example embodiment, the method comprises the following further steps:

- filling each pocket 12 of the plurality of pockets 12 with a dose 30 of infusion product;

- positioning a sealing sheet 13 on the multilayer sheet 10;

- sealing the pockets 12 of the plurality by securely joining disc-shaped portions of the sealing sheet 13 to the annular flange 3 of the pocket 12.

Preferably, the step of separating the pockets 12 from the multilayer sheet 10 causes the corresponding disc-shaped portions of the sealing sheet 13 to be also separated, thereby forming the corresponding sealing covers 40 and thus forming the capsules 50 separated directly from the multilayer sheet 10 and from the sealing sheet 13.

In an example embodiment, the method comprises a step of scoring or cutting the multilayer sheet 10 in one or more zones of weakness of the sheet, interposed between the forming zones.

As regards the cup 1 , attention is drawn to the following.

Advantageously, the annular flange 3 has, on its rear face 3a, an annular groove 4 which extends around the axis "X". The groove 4 is configured to act in conjunction with an end edge of a pressure hood element of an infusion machine to create a hermetic seal during infusion of the coffee contained in the cup 1.

The groove 4, which extends along a circular line centred on the axis X, is therefore axisymmetric.

The groove 4 has a profile which, in transversal cross section (that is to say, perpendicularly to the line which the groove 4 extends along) is defined at least partly by a circular arc. As shown in the drawings, the groove 4 has a width L1 (that is, a radial extension) of between 0.15 mm and 0.45 mm, preferably approximately 0.25 mm, measured diametrically relative to the axis X.

The groove 4 has a depth H1 of between 0.15 mm and 0.40 mm, preferably approximately 0.24.

Further, the annular groove 4 is located at a position spaced from an annular joining zone 5 (that is, a transition zone of connection) joining to each other the upper edge 2b of the containment body 2 and the annular flange 3. Preferably, the annular groove 4 has an inner fastening edge 4a spaced from the annular joining zone 5 by a distance "M" of between 0.15 and 0.4 mm, preferably approximately 0.33 mm.

Preferably, therefore, the rear face 3a of the flange, in the proximity of the body 2 of the cup 1 defines a border 51 , that is, an annular zone interposed between the body 2 (that is, the upper edge 2b of the containment body 2) and the groove 4 (that is, the fastening edge 4a of the groove 4). The border 51 is preferably flat, that is, without protrusions or grooves, and is substantially perpendicular to the axis X, that is to say, 5 it extends radially. The width of the border 51 is labelled M. Preferably, the transition zone 5 which joins to each other the upper edge 2b of the containment body 2 and the border 51 of the annular flange 3, defines a curved profile, and more preferably, a circular arc.

The groove has three portions: an inside wall 4c (proximal to the body 2 of0 the cup 1 ), an outside wall 4d (distal from the body 2 of the cup 1 ), and a bottom wall 4e interposed between the inside wall 4c and the outside wall 4d.

Preferably, also, the annular flange 3 has on its rear face 3a an annular ridge or tooth 6. Preferably, the ridge 6 is adjacent to the groove 4.5 Preferably, the ridge 6 is further towards the outside (that is, further away from the axis X) than the groove 4. The annular ridge 6 extends (axially) away from the rear face 3a of the annular flange 3 (that is, it protrudes from the rear face 3a of the annular flange 3).

Preferably, the annular ridge 6 has a fastening edge 6a coinciding with the o outlet edge 4b of the groove 4.

Preferably, the annular ridge 6 has three portions: an inside wall 6b (proximal to the body 2 of the cup 1 ), an outside wall 6c (distal from the body 2 of the cup 1 ), and a top wall 6d interposed between the inside wall 6b and the outside wall 6c.

5 The annular ridge 6 has a width L2 (that is, a radial extension) of between

1.0 mm and 1.4 mm, preferably approximately 1.17 mm, measured diametrically relative to the axis X, and a depth H2 of between 0.25 mm and 0.70 mm, preferably approximately 0.34 mm,.

In other words, the top wall 6d of the ridge 6 (together with the outside wall o 6c) has a width equal to L2.

Preferably, the rear face 3a of the annular flange 3 has, in a transversal cross section in a plane through the axis, a profile having a rectilinear transition stretch T joining the annular groove 4 and the annular ridge 6 to each other and directed towards the axis X. Preferably, the rectilinear stretch T is parallel to the axis X. It might, however, also be inclined relative to the axis X, for example at an angle of inclination in the interval [0; 20] sexagesimal degrees made with the direction of the axis X towards the upper edge 2b of the body 2 of the cup, that is, towards the cover 40 of the capsule).

The rectilinear stretch T might be substituted by a change in concavity (inflection) with a vertical tangent, that is to say, parallel to the axis X.

Preferably, the rectilinear stretch T is formed by the outside wall 4d of the groove 4 and the inside wall 6b of the ridge 6, which are arranged in sequence relative to each other and aligned in parallel with the axis X. The groove 4 and the ridge 6 extend around the axis X of the cup.

Preferably, the rectilinear stretch T formed by the outside wall 4d of the groove 4 and the inside wall 6b of the ridge 6 has a diameter D of between 30.34 mm and 30.74 mm, more preferably of approximately 30.54 mm. Preferably, the inside wall 4c and the bottom wall 4e of the groove 4 define a curved profile, and more preferably, a circular arc. Preferably, the outside wall 4d of the groove 4 is rectilinear and parallel to the axis X.

Preferably, the width L2 of the ridge 6 is greater than the width L1 of the groove 4. Preferably, the width L2 of the ridge 6 is greater than the width M of the border 51. Preferably, the width L2 of the ridge 6 is substantially equal to (or greater than) the sum of the width L1 of the groove 4 and the width M of the border 51.

Preferably, the ratio between the width L2 and the quantity (M+L1 ) is in the interval [2, 3.5].

Preferably, the top wall 6d of the ridge 6 is flat or substantially flat.

Preferably, the wall 6c (the outside wall of the ridge 6) is inclined to form a bevel joining the ridge 6 to a portion of the of the rear face 3a of the flange

3 on the outer side of the ridge 6 itself. Preferably, the wall 6c is inclined relative to the axis X at an angle of between 0 and 45 sexagesimal degrees.

As regards the shape of the rear face 3a of the flange 3, it should be noted that there are important aspects for the capsule seal.

For example, the fact that the rear face 3a of the flange 3 defines, in sequence, starting from the body 2 of the cup 1 , the transition zone 5, the border 51 , the groove 4 and the ridge 6 guarantees an effective seal for all the capsules and at all points of interface between the cup 1 and the presser of the infusion machine (or coffee brewing machine).

In light of this, it should be noted that the profile of the cup (at the flange 3) and/or that of the presser might not be perfectly circular.

This, besides possible centring errors between the cup 1 and the presser in the coffee brewing machine, means that the presser, depending on circumstances and the zone of the presser itself (within the 360 degrees of extension of the profile of the presser) might come into contact with different zones of the rear face 3a of the flange.

Whatever the case, these zones will be between the transition zone 5 and the ridge 6 (border 51 and ridge 6 included). This guarantees a good seal between the presser and the rear face 3a of the flange 3 at all times.

Preferably, the containment body 2 externally defines a step 7 at the top of it close to the upper edge 2b and/or a chamfer 8 located in the lower portion of the containment body 2.

The step 7 defines an external shoulder 7a designed to allow the cup 1 to rest on the annular flange 3 of an identical cup underneath it.

The chamfer 8, on the other hand, preferably has a rounded shape and defines a local reduction in the diameter of the containment body 2 in the direction of the bottom 2a, giving the containment body 2 an outer shape which tapers towards the bottom 2a.

The containment body 2 and the annular flange 3 are made in one piece. The containment body 2 and the annular flange 3 have a multilayer structure comprising: - an inner layer made of a plastic material, defining the front face 3b of the annular flange 3 and the inside surface of the containment body 2;

- an outer layer made of a soft plastic material whose hardness is preferably less than that of the inner layer;

- a middle layer, between the inner layer and the outer layer, made of a material impermeable to oxygen and aromas.

The inner layer is made of a material which can confer good rigidity on the bottom 2a of the containment body 2 when the bottom 2a itself is subjected to the cutting action of specific knives (not illustrated). This material is preferably polypropylene.

The outer layer is made of a material which is deformable enough to allow it to adhere to the corresponding upper edge of the pressure hood element of the infusion machine. This material preferably has a hardness which is less than that of the material the first layer is made of. The outer layer is made preferably of polyethylene. Alternatively, the outer layer might be made of polypropylene or other materials.

It should be noted that the outer layer of the cup (that is, of the flange 3 of the cup) is made of a soft, deformable material. This material can undergo at least partly plastic deformation. Preferably, the material the outer layer is made of can also undergo at least partly plastic deformation. In light of this, it should be noted that the elasticity modulus of the layer is preferably less than 1400 MPa (that is, the elasticity modulus of the layer is included in the interval [0, 1400] MPa). The middle layer is preferably made of EVOH.

Preferably, in order to increase the rigidity of the containment body 2, the latter may have stiffening ribs 9 arranged radially away from the axis X. Preferably, the stiffening ribs 9 are located on the side wall 2c of the containment body 2.