DEVICE AND METHOD FOR ASSEMBLING CAPSULES FOR EXTRACTING

BEVERAGES

Technical field

This invention relates to a device and a method for assembling the capsules for extracting beverages.

More specifically, this invention relates to disposable capsules for extracting beverages such as, for example, coffee, tea, milk or the like.

Background art

The capsules comprise a main body for containing the product or aromatic substance, such as ground coffee or other products in powder form such as milk or tea, from which the beverage is derived.

The main body is equipped with a chamber for containing the aromatic substance having an inlet opening through which the aromatic substance is inserted.

The inlet opening may be sealed using a closing element in the form of a cap or sheet of metal material, such as, for example, aluminium.

The capsules of the above-mentioned type comprise at least one filter located inside the product containment chamber and a base element coupled with the main body. The capsules of the above mentioned type are obtained by assembling the component parts, such a the main body, the filter and the base element.

There are prior art assembly devices comprising a line for feeding a plurality of trays each of which has a plurality of recesses positioned according to a plurality of rows parallel to each other.

The device comprises a plurality of stations for feeding respective components, such as the main body, the filter and the base element, by which the feed line conveys the trays for making the capsule.

The feed stations are located along the feed line according to the sequence for stacking the components forming the capsule, in particular, the base element is fed from the respective station, then the main body, which is positioned on the base element, and then the filter, which is inserted inside the main body.

The above-mentioned components are fed by "pick and place" robots which, however, have low production speeds of the prior at assembling device.

Disclosure of the invention

The aim of this invention is to provide a device and a method for assembling capsules for extracting a beverage which has a greater production speed compared with the prior art, as described in the independent claims 1 and 1 1 .

Brief description of the drawings

The invention is described below with reference to the accompanying drawings, which illustrate a non-limiting embodiment and in which:

- Figure 1 is a schematic perspective view of the device for assembling capsules for extracting beverages according to this invention;

- Figure 2 is a scaled-up schematic perspective view of a first detail of the device illustrated in Figure 1 ;

- Figure 3 is a scaled-up view of a detail of Figure 2;

- Figure 4 is a scaled-up schematic perspective view of a second detail of the device illustrated in Figure 1 ;

- Figure 5 is a scaled-up schematic perspective view of a third detail of the device illustrated in Figure 1 ;

- Figure 6 is a scaled-up view of a detail of Figure 5;

- Figure 7 is a further scaled-up view of a detail of Figure 5;

- Figure 8 is a scaled-up schematic perspective view of a fourth detail of the device illustrated in Figure 1 ; - Figure 9 is a scaled-up schematic perspective view of a fifth detail of the device illustrated in Figure 1 ;

- Figures 10 and 1 1 are schematic perspective views of respective details of Figure 8 during the step of rejecting the capsules.

Detailed description of the preferred embodiments of the invention

The numeral 1 denotes a device for assembling capsules for extracting beverages, such as coffee, tea, milk or the like.

Each capsule 2 comprises at least one main body 3 containing an aromatic substance from which the beverage is extracted, the main body 3 having a base 3b. The capsule 2 comprises a filtering element 4 positioned at the base 3b of the main body 3.

The main body 3, the filtering element 4 and the base element 5 define at least partly the main components 3, 4, 5 of the capsule 2.

The main body 3 has a chamber 6 for containing the product or extract provided with an inlet opening 3a through which the product or aromatic substance is inserted inside.

The chamber 6 of the main body 3 is designed to contain, for example, ground coffee or other products in powder form such as, for example, milk or tea.

Preferably, the inlet opening 3a is sealed using a closing element in the form, for example, of a cap or sheet of metal material, such as, for example, aluminium.

In use, hot liquid is injected inside the capsule 2, in particular inside the main body 3 through the inlet opening 3a. The liquid passes through the chamber 6 containing the aromatic substance which, by infusion, becomes a beverage which is extracted from the base 3b of the main body 3, after passing through the filtering element.

In the preferred embodiment, the capsule 2 comprises a base element 5 located at the base of the main body 3.

The base element 5 can form the dispenser of the beverage extracted from the main body 3. Alternatively, the base element 5 can form an element for filtering the beverage.

With reference to Figure 1 , the device comprises a line 7 for feeding the above- mentioned components 3, 4, 5 and means 8 for positioning the above-mentioned components 3, 4, 5 along the feed line 7.

The feed line 7 comprises a conveyor 9, which moves continuously, forming a path P for feeding the above-mentioned components 3, 4, 5.

The path P defined by the conveyor is a closed path, preferably in the shape of a ring. Along the feed line 7 there are a plurality of stations 10, 1 1 , 12 for feeding, respectively, the main body 3, the filtering element 4 and the base element 5.

More specifically and preferably, the station 10 for feeding the main body 3 is positioned upstream of the station 12 for feeding the base element 5, according to the feed direction of the conveyor 9.

The station 1 1 for feeding the filtering element 4 is positioned downstream of the station 10 for feeding the main body 3 and the station 12 for feeding the base element 5, according to the feed direction of the conveyor 9.

In other words, in the preferred embodiment illustrated, the station 12 for feeding the base element 5 is positioned between the station 10 for feeding the main body 3 and the station 1 1 for feeding the filtering element 4.

As illustrated in Figures 2 and 4, the stations 10, 1 1 , 12 for feeding the main body 3 and the base element 5 feed the respective components to the conveyor 9.

The device 1 has an outfeed station 16 at which the capsules 2, obtained from the assembly of the main body 3 with the filtering element 4 and the base element 5, are released.

More specifically, the feed line 7 comprises a first assembly station 14 at which the main bodies 3 are assembled with the respective base elements 5 and a second assembly station 15, positioned downstream of the first assembly station 14, at which the filtering elements 4 are assembled with the respective main bodies 3.

More specifically, the path P comprises at least one first section T1 along which the conveyor 9 moves forward solely the main bodies 3 and a second section T2, positioned downstream of the first section T1 , along which the conveyor 9 moves forward only the base elements 5.

The first section T1 extends from the station 10 for feeding the main body 3 to the station 12 for feeding the base element 5.

The second section T2 extends from the station 12 for feeding the base element 5 to the first assembly station 14.

The path P also comprises a third section T3, positioned downstream of the second section T2, along which the conveyor 9 feeds the base elements 5 assembled with a respective main body 3.

The third section T3 extends from the first assembly station 14 to the second assembly station 15.

The path P comprises a fourth section T4 along which the filtering element 4 is inserted in the main body 3, which is, in particular, assembled with the respective base element 5.

The third section T4 extends from the second assembly station 15 to the outfeed station 16.

The conveyor 9 comprises a plurality of recesses 13 for housing at least one of the components 3, 5 which are positioned one after the other to define a single row. The housing recesses 13 convey the components 3, 4, 5 of the capsule 2 along the path P towards the outfeed station 16, passing through the above-mentioned stations 10, 1 1 , 12 for feeding the main body 3, the filtering element 4 and the base element 5 and through the first and second assembly stations 14, 15.

Advantageously, the positioning means 8 are synchronized with the conveyor 9 for assembling together the above-mentioned components 3, 4, 5 on the conveyor 9. The positioning means 8 comprise first means 17 for transferring the main bodies 3 and second means 22 for transferring the filtering elements 4, operating along respective sections of the path P in common with the conveyor 9.

The positioning means 8 move forward along at least one section of the path P in common with the conveyor 9. More specifically, along the above-mentioned sections of the path P in common with the conveyor 9, the first and second transfer means 17, 22 move forward, respectively, the main bodies 3 and the filtering elements 4 and simultaneously the conveyor 9 moves forward the base elements 5.

More specifically, along the second section T2 of the path P, the first transfer means 17 hold the main bodies 3 raised above the respective base elements 5 with which they are assembled.

In practice, the first transfer means 17 pick up the respective main bodies 3 from the first section T1 of the path P, keeping them raised along the second section T2 of the path P and release the main bodies 3 on the respective base elements 5 along the third section T3, assembling them.

Generally speaking, the first transfer means 17 pick up the main bodies 3 from the first section T1 of the path P to place them along the third section T3 of the path P. The first transfer means 17 pick up the main bodies 3, which are fed from the respective feed station 10, from the conveyor 9 to free the respective recesses 13 of the first section T1 of the path P, in such a way that they are free to receive the base elements 5 fed from the respective feed station 12 at the second section T2.

The first transfer means 17 are connected by a kinematic mechanism with the conveyor 9 in such a way that each seat 13 of the conveyor 9 corresponds to a transfer means 17.

The first transfer means 17 are supported and rotated by a carousel 18 rotating about its vertical axis 18a.

The first transfer means 17 rotate about the vertical axis 18a in the same direction as the feed direction of the conveyor 9.

Cam means, not illustrated, allow the raising and lowering of the first transfer means 17 during their rotation about the vertical axis 18a of the carousel 18.

Each transfer means 17 comprises a piston 19 movable along a direction parallel to its own vertical axis 19a.

More specifically, the piston 19 translates along its vertical axis 19a away from and towards the conveyor 9 for raising and lowering the main bodies 3 relative to the base elements 5 housed in the respective recesses 13 of the conveyor 9.

Each piston 19 comprises a relative head 20 equipped with elements 21 for engaging with a respective main body 3 which activate in order to retain the main body 3 and they deactivate to release it.

Preferably, the engagement elements 21 can be extracted from the respective head 20 in a direction at right angles to the axis 18a of the piston 18.

The second transfer means 22 are positioned downstream of the first transfer means 17, in the direction of rotation of the conveyor 9.

The second transfer means 22 convey the filtering elements 4 from the respective feed station 1 1 to the second assembly station 15. More specifically, along part of the third section T3 of the path P, the second transfer means 22 hold the filtering elements 4 raised above the respective main bodies 3 with which they are assembled.

The second transfer means 22 are supported by a drum 25 rotating about a vertical axis 22a.

The second transfer means 22 rotate about the vertical axis 22a in the same direction as the feed direction of the conveyor 9.

The second transfer means 22 comprise a plurality of punches 23 rotating about the vertical axis 22a.

The second transfer means 22 are connected by a kinematic mechanism with the conveyor 9 in such a way that each seat 13 of the conveyor 9 corresponds to a punch 23.

Each punch 23 retains a respective filtering element 4, preferably by suction.

It should be noted that the first and second transfer means 17, 22 are positioned on curvilinear sections of the path P.

In use, the conveyor 9 moves forward continuously and each seat 13 picks up a respective main body 3 from the respective feed station 10.

With reference to Figure 2, the recesses 13 convey the respective main body from the feed station 10 towards the station 1 1 for feeding the filtering element 4, moving along the first section T1 of the path P.

At the same time, the piston 19 positioned on the respective seat 13 starts to move parallel to the respective axis 19a towards the seat 13 of the conveyor 9 and of the main body 3 positioned inside the seat 13, until the respective head 20 is positioned inside the chamber 6 of the main body 3, as illustrated in Figure 3.

At this point, the engagement elements 21 are activated, which withdraw from the head 20 until engaging with the walls of the chamber 6 of the main body 3.

Once the engagement elements 21 are holding the main body, the piston 19 starts to move parallel to the respective axis 19a away from the seat 13 of the conveyor 9, raising the main body 3, freeing the respective seat 13.

The seat 13 is now be free to accommodate a respective base element 5 fed from the respective feed station 12.

As shown in Figure 4, the free seat 13 picks up a respective base element 5 from the respective feed station 10 and starts to moves along the second section T2 of the path P.

Along the second section T2 the piston 19 located at the respective seat 13 keeps the main body 3 raised above the base element 5 housed in the above-mentioned seat 13.

As illustrated in Figure 5, before the seat 13 reaches the first assembly station 14, the piston 19 starts again to move parallel to the respective axis 19a, carrying the main body 3 towards the seat 13 of the conveyor 9 and of the base element 5 positioned inside the seat 13.

At the first assembly station 14, with reference to Figure 6, the piston 19 positions the main body 3 on the base element 5 and imparts a slight pressure on the main body 3, using the relative head 20, so that the main body 3 and the base element 5 assemble in a snap-on fashion.

Downstream of the first assembly station 14, each seat 13 conveys a respective base element 5 assembled to the main body 3 along the third section T3 of the path P. At this point, the engagement elements 21 of each piston 19 withdraw disengaging the respective main body 3.

Next, each piston 19 starts to move parallel to the respective axis 19a away from the respective seat 13 of the conveyor 9, until the head 20 is positioned outside the respective main body 3, as shown in Figure 7.

The piston 19, by the rotation of the carousel 18, passes from the third section T3 of the path P to the first section T1 of the path P to start again the operations described above.

It should be noted that to pass from the third section T3 to the first section T1 , each piston 19 is rotated about the axis 18a outside the path P of the conveyor 9.

The recesses 13 of the conveyor 9 transfer the base elements 5 from the first assembly station 14 towards the second assembly station 15.

Upstream of the second assembly station 15, the second transfer means 22 move along part of the section T3 of the path P shared with the conveyor 9.

More specifically, while the recesses 13 of the conveyor 9 reach the second assembly station 15, each punch 23 picks up a respective filtering element 4 and conveys it to the second assembly station 15, as shown in Figure 8.

More specifically, along part of the section T3 of the path P, each punch 23 is moved towards the respective seat 13 of the conveyor 9 for inserting the respective filtering element inside the main body, in particular inside the chamber 6.

At the second assembly station 15, with reference to Figure 9, the piston 23 positions the respective filtering element 4 in the main body 3 and imparts a slight pressure on the filtering element 4 so that the filtering element 4 is inserted in the main body 3 in a snap-on fashion.

Downstream of the second assembly station 15, the recesses 13 move along the fourth section T4 of the path P to the outfeed station 16.

More specifically, each seat 13 houses a capsule 2, comprising a base element 5, a main body 3 and a filtering element 3 assembled together.

At this point, each punch 23 moves away from the respective seat 13 of the conveyor 9, until it is positioned outside the respective main body 3. Once the punch 23 is positioned outside the respective main body 3 it reaches the station 1 1 for feeding the filtering element 4 by rotation of the vertical axis 22a to start again the operations described above.

The recesses 13 convey the respective capsules 2 to the outfeed station 16 at which they are expelled from the respective seat 13, freeing it.

Figures 10 and 1 1 show the outfeed station 16 of the conveyor 9 at which the device 1 comprises a gate 24 normally positioned in a closed condition, to facilitate expulsion of the capsules 2 from the respective seat 13.

The gate 24 moves from the closed position to an open position to allow rejection of capsules 2 detected as defective.

More specifically, downstream of the second assembly station 15, the device 1 comprises a unit, not illustrated, preferably of an optic type, for controlling the completed capsules 2, which is able to detect the defective capsules 2 to be rejected. The control unit, not illustrated, is logically connected to a command and control unit, not illustrated, logically connected to the gate 24 for controlling the opening once the capsule 2, considered as defective by the control unit, reaches the outfeed station 16. The defective capsule 2 continues along the path P of the conveyor 9 drawn by the respective seat 13 and is expelled from the seat 13 downstream of the outfeed station 16 at a reject station, not illustrated.

The reject station, not illustrated, is positioned upstream of the stations 10, 12 for feeding the main body 3 and the base element 5, respectively, according to the feed direction of the conveyor 9.

This invention also relates to a method for assembling the capsules for extracting beverages.

The method comprises a step of moving forward the above-mentioned components 3, 4, 5 along a path P and a step of mutually positioning with each other the above-mentioned components 3, 4, 5 during the step of moving forward the components 3, 4, 5.

More specifically and advantageously, the step of moving forward the components 3, 4, 5 is performed continuously along the path P and the step of positioning the components 3, 4, 5 is synchronised with the step of moving forward for assembling together the components 3, 4, 5 along the path P.

The step of positioning the components 3, 4, 5 comprises a step of keeping raised the main bodies 3 on the respective base elements 5 during the step of moving forward the components 3, 4, 5 along the path P.

The step of positioning the components 3, 4, 5 comprises a step of keeping raised the filtering elements 4 on the respective main bodies 3 during the step of moving forward the components 3, 4, 5 along the path.

In the preferred embodiment, the step of moving forward the above-mentioned components 3, 4, 5 comprises a first step of moving forward solely the main bodies 3 along a first section T1 of the path P, a second step of moving forward solely the base elements 5 along a second section T2 of the path P and a third step of moving forward the base elements 5 assembled with a respective main body 3 along a third section T3 of the path P.

More specifically, the step of transferring the main bodies 3 from the first section T1 of the path P to the third section T3 of the path P.

The step of transferring the main bodies 3 comprises a step of freeing the second section T2 of the path from the main bodies 3 for receiving the base elements 5. Advantageously, the device 1 according to the invention reaches production speeds greater than those of the prior art due to the continuous motion of the conveyor 9 and the synchronisation of the first and second transfer means 17, 22 with the conveyor 9. In a variant embodiment of the device 1 , the pistons 19 of the first transfer means 17 pick up the main bodies 3 from the respective feed station 10 in a position already raised relative to the seats 13 of the conveyor 9.

It should be noted, lastly, that in a first variant embodiment not illustrated, the device 1 comprises the station 1 1 for feeding the filtering elements 4 positioned between the station 10 for feeding the main body 3 and the station 12 for feeding the filtering element 5.

In this alternative embodiment not illustrated, the second transfer means 22 are positioned upstream of the first transfer means 17, according to the feed direction of the conveyor 9, for inserting inside the main bodies 3 the respective filtering elements 4 and, subsequently, placing the main body 3, housing inside the filtering element 4, on the respective base element 5.