Capsules

1. A method of assembling a filter element with a cup-shaped capsule body using a combined weld-head and former, comprising the steps of:

a) positioning the filter element at or near a mouth of the cup-shaped capsule body;

b) moving the combined weld-head and former so as to contact and drive the filter element into the cup-shaped capsule body;

c) wherein, during step b), the filter element is deformed by a spring-loaded former of the combined weld-head and former to form a cup-shaped filter element; and

d) using a weld-head of the combined weld-head and former to bond the cup-shaped filter element to the cup-shaped capsule body;

wherein, during step d), a portion of the spring-loaded former is disposed within the cup-shaped capsule body and a portion of the weld-head is disposed within the cup-shaped capsule body.

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

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

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

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

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

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

8. A method as claimed in claim 7 , wherein, during step d), at least a portion of the cup-shaped capsule body is softened by the heated portion of the weld-head, thereby allowing the weld-head to move further into the cup-shaped capsule body.

9. A method as claimed in claim 8 , wherein during said further movement of the weld-head into the cup-shaped capsule body, further movement of the spring-loaded former into the cup-shaped capsule body is limited or avoided by allowing the spring-loaded former to move relative to the weld-head against the spring bias.

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

11. A method as claimed in claim 1 , comprising the further step of:

e) withdrawing the combined weld-head and former from the cup-shaped capsule body.

12. A method as claimed in claim 11 , wherein during step e) the spring-loaded former flexes to aid decoupling of the spring-loaded former from the cup-shaped filter element.

13. A method of making a beverage capsule using the cup-shaped capsule body with a filter element assembled according to the method of claim 1 , comprising the steps of:

i) filling a portion of one or more beverage ingredients into the cup-shaped filter element bonded to the cup-shaped capsule body; and

ii) closing and sealing the cup-shaped capsule body using a lid.

14. A method as claimed in claim 1 , wherein the spring-loaded former can move toward the weld-head against a spring bias; and wherein a distance between the weld-head and a bottom of the spring-loaded former can vary during step d) by allowing the spring-loaded former to move toward the weld-held against the spring bias to limit movement of the former into the cup-shaped capsule body.