COMPOSTABLE TOP LID STRUCTURE FOR A BEVERAGE PREPARATION CAPSULE

Abstract

The invention relates to a capsule (100) for preparing a beverage in a beverage production machine. The capsule (100) comprises a capsule body (200) with a sidewall (210) delimiting a chamber (250) for containing a substance (500) for the preparation of the beverage and an injection wall (220) for injecting a fluid in the chamber (250) for preparing the beverage upon interaction of the fluid with the substance (500). The capsule (100) further comprises a delivery wall (300) that is connected to the capsule body (200) to close the chamber (250). The delivery wall (300) comprises, in a layered manner, a retention layer (320) for being opened upon interaction with opening elements under the effect of rising pressure of fluid being injected into the capsule (100) and a filter layer (310) for filtering out particles from the prepared beverage. Each of the filter layer (310) and the retention layer (320) is made of biodegradable material. The filter layer (310) is provided opposite to the chamber (250) with respect to the retention layer (320). The invention also relates to a method for manufacturing the capsule (100) and use of the capsule (100) for preparing a beverage.

Claims

1. A capsule for preparing a beverage in a beverage production machine, wherein the capsule comprises: a capsule body with a sidewall defining a chamber for containing a substance for the preparation of the beverage; an injection wall for injecting a fluid in the chamber for preparing the beverage upon interaction of the fluid with the substance; and a delivery wall being connected to the capsule body to close the chamber, the delivery wall comprising in a layered manner: a retention layer being adapted to be opened upon interaction with opening elements under the effect of rising pressure of the fluid being injected into the capsule, and a filter layer for filtering out particles from the prepared beverage dispensed via the delivery wall, wherein each of the filter layer and the retention layer is made of biodegradable material, and wherein the filter layer is provided opposite to the chamber with respect to the retention layer.

2. The capsule according to claim 1, wherein each of the filter layer and the retention layer is made of a different biodegradable structure and/or fibre orientation.

3. The capsule according to claim 1, wherein the retention layer is configured such that it provides a bidirectional barrier against liquid and/or gaseous substances entering and/or leaving the chamber.

4. The capsule according to claim 1, wherein the retention layer is configured such that it is resilient against a built-up pressure in the chamber between 1 and 20 bar.

5. The capsule according to claim 1, wherein the filter layer is made of a compostable and/or non-woven material.

6. The capsule according to claim 1, wherein the retention layer is made of a material that is compostable and has a defined closed fibre structure.

7. The capsule according to claim 1, wherein the retention layer and the filter layer are at least partially joined to each other on opposite sides thereof.

8. The capsule according to claim 1, wherein the delivery wall is connected to the capsule body.

9. The capsule according to claim 1, wherein the capsule body comprises a protective layer for providing a bidirectional barrier against moisture and/or oxygen and/or for providing a sealing interface between the capsule body and the injection wall, wherein the protective layer is made of a biodegradable material.

10. The capsule according to claim 1, wherein the capsule body and/or the injection wall comprise a layered and/or laminated structure.

11-15. (canceled)

Description

4. BRIEF DESCRIPTION OF DRAWINGS

[0058] Further features, advantages and objects of the invention will become apparent for the skilled person when reading the following detailed description of embodiments of the invention and when taking in conjunction with the figures of the enclosed drawings. In case numerals have been omitted from a figure, for example for reasons of clarity, the corresponding features may still be present in the figure.

[0059] FIG. 1 shows a schematic exploded view of a capsule according to an embodiment of the invention.

[0060] FIG. 2 shows a line chart of a pressure profile of the pressure inside the capsule of FIG. 1 over time.

[0061] FIG. 3 shows a comparative chart for two different capsule configurations, with one configuration displaying the pressure profile of the capsule of the invention of FIG. 1 (as illustrated in FIG. 2), while the other configuration shows the pressure profile of a comparative capsule, which has a delivery wall, where the order of the respective delivery wall layers is reversed to the delivery wall of the capsule of FIG. 1.

[0062] FIG. 4 shows a line chart of pressure profiles for typical paper materials.

[0063] FIG. 5 shows a line chart of pressure profiles for typical non-woven materials.

5. DETAILED DESCRIPTION

[0064] The figures show different views and aspects of an embodiment of a capsule 100 for preparing a beverage in a beverage production machine in accordance with the present invention. The capsule 100 may have a composite structure and/or may be made from a composite material, which preferably may consist entirely from biodegradable and/or compostable materials.

[0065] The capsule 100 comprises a capsule body 200 with a sidewall 210. The capsule body 200 may have any shape or form. For example, the capsule body 200 may have a form that is suitable for the capsule 100 being inserted in a capsule holder of a (known) beverage production machine. The capsule body 200 may have a truncated-, cup- or bowl-shaped form. The capsule body 200 may have a circular cross-section. Thereby, for example, pressure related forces exerting on the capsule body 200 can be absorbed.

[0066] The capsule body 200 comprises a sidewall 210. The sidewall 210 delimits a chamber 250 inside the capsule 100. The sidewall 210 may be provided such that it encloses a continuous space inside the capsule body 100. This is shown exemplarily in FIG. 1.

[0067] The chamber 250 is arranged to receive and store a substance 500 for the preparation of the beverage. Therein, the substance 500 may be any type of (solid, liquid, at least partially soluble and/or percolate-able) matter of a particular or definite chemical constitution. Examples for substances may be roasted ground coffee, instant coffee, tealeaves, syrup concentrate, fruit extract concentrate, a chocolate product, dehydrated edible substances, and/or combinations thereof. Accordingly, examples for beverages that may be prepared may be coffee- or chocolate-based drinks, or other similar types of food. However, the above examples for the substance 500 and beverages are not to be seen as a complete enumeration. Instead, various other examples are conceivable.

[0068] The capsule body 200 may have an opening 230 to the chamber 250. The opening 230 may be on at least one of the capsule body's 200 opposite ends. For example, the substance 500 may be filled inside the capsule 100 through the opening 230. The substance 500 may fill the chamber 250 entirely. However, there may be a free space between the opening 230 and the filling level of the substance 500, which may be filled with an inert gas for keeping the substance 500 fresh. Preferably, a rim portion 211 of the sidewall 210 may delimit the opening 230. The rim portion 211 may have the form of a flange and extend from the sidewall 210, preferably away from the chamber 250. In operation, the capsule 100 may be placed on the rim portion 211 inside a capsule holder of a beverage production machine.

[0069] The sidewall 210 may be provided such that it forms a continuous mantle surface of the capsule body 200. For example, the sidewall 210 may have an inside surface facing the chamber 250 and an outside surface facing away from the chamber 250.

[0070] A protective layer 400 for providing a preferably bidirectional barrier against moisture and/or oxygen for the substance 500 may be provided on the capsule body 200 and/or the sidewall 210. In FIG. 1, the protective layer 400 is exemplarily illustrated as being provided as a liner on the inside surface of the sidewall 210, which may extend up to and over the rim portion 211. The protective layer 400 may be provided additionally or alternatively on the outside surface of the sidewall 210. Therein, the protective layer 400 may be made of a biodegradable and preferably compostable material, such as biopolymers or bioplastic families such as PHB and co-polymers, PBS, PBS-A, PLA, PBAT, Cellulose Acetate, starch, PVOH, and it may include polymers where at least one of the monomer units is vinyl alcohol, as well as compounds or laminates of any of the above mentioned materials. Preferably, the protective layer 400 may be made of a food safe material (FCS, FCMs).

[0071] For example, the capsule body 200 may be made of (laminated) (wet/dry) moulded pulp fibre. Preferably, the capsule body 200 may be made of a biodegradable and/or compostable material. The capsule body 200 may be made of a food safe material (FCS, FCMs). The capsule body 200 may comprise a layered and/or laminated structure. For example, the capsule body 200 may be relatively stiff or rigid so not to collapse during operation in a beverage production machine or during storage. The layered and/or laminated design may provide the capsule body 200 with additional rigidity and/or stiffness in comparison to other designs. Therein, the moulded pulp fibre may be a composite having an additional substrate, such as biodegradable resin, laminated on the capsule body 200. For example, a laminated structure of the capsule body 200 may be created by providing the protective layer 400 thereon. However, it is also conceivable that the capsule body 200 may comprise, for example, in addition to the protective layer 400 a further laminate layer.

[0072] The capsule 100 comprises an injection wall 220 for injecting a fluid in the chamber 250 for preparing the beverage upon interaction of the fluid with the substance 500. This is exemplarily illustrated in FIG. 1.

[0073] The injection wall 220 may be provided on an opposite end of the capsule body 200 to the opening 230. The injection wall 220 may be provided integrally or separately with the capsule body 200. Hence, the capsule body 200 and the injection wall 220 may be made up of separate pieces or may be integrally formed as a one-piece. The injection wall 220 may form a tapered end portion of the capsule body 200. The injection wall 220 may be configured to be perforated by blades of the coffee production machine such that the blades provide openings for the fluid injection. Preferably, the fluid may be a liquid or a liquid/gas mixture, such as water or milk. As the capsule body 200, the injection wall 220 may comprise also the above-described protective layer 400. It is also conceivable, that the injection wall 220 may comprise (small) openings through which blades of the coffee production machine can enter and pierce the protective layer 400. Similar to the capsule body 200, the injection wall 220 may comprise a layered and/or laminated structure and may be made of (laminated) moulded pulp fibre and/or a food safe material (FCS, FCMs).

[0074] The capsule body 200 and the injection wall 220 may be provided such that the chamber 250 is closed (sealed) preferably from at least three sides as shown in FIG. 1. The capsule body 200 and the injection wall 220 maybe provided such that the injected fluid is dispersed evenly in the chamber 250 along the sidewall 210.

[0075] The capsule 100 comprises a delivery wall 300, which is connected to the capsule body 200 to close the chamber 250. This is exemplarily indicated in FIG. 1.

[0076] For example, the delivery wall 300 may be connected to the rim portion 211. This may be accomplished, for example, by heat-sealing or adhesive bonding. Therefore, an adhesive layer or sealable coating may be provided between the delivery wall 300 and the capsule body 200, with which (adhesive layer) the capsule body 200 and the delivery wall 300 may be attached (joined) to each other. The mentioned sealable/adhesive layer may cover the full area of the retention layer 320 on the side closest to capsule body 200. The adhesive layer may form part of the delivery wall 300 or be an element separate from the capsule body 200 and the delivery wall 300. For example, the adhesive layer may form part of the protective layer 400 or may be provided in addition to it. The delivery wall 300 may be attached to the capsule body 200 via the rim portion 211. For example, the adhesive layer may extend over the opening 230 such that it covers the opening 230 and overlaps the rim portion 211. Also, the adhesive layer may cover the entire surface of the delivery wall 300, the surface which is directed towards (i.e. faces) the chamber 250. The delivery wall 300 may be provided opposite to the injection wall 220 with respect to the chamber 250. The delivery wall 300 and the injection wall 220 may be provided with respect to each other such that in operation the injected fluid traverses the capsule 100 in the order of the injection wall 220, the chamber 250 (and, if available, the substance 500 contained therein), and the delivery wall 300. The chamber 250 may be fully enclosed by the delivery wall 300 (on one end), the injection wall 220 (on an opposite end thereof) and the sidewall 210 (along/surrounding the sides between the two opposite ends). The delivery wall 300 may at least partially, preferably entirely, extend over the opening 230. Preferably, the delivery wall 300 may (at least partially) overlap (with) the rim portion 211.

[0077] The delivery wall 300 is provided in a layered manner as exemplarily shown in FIG. 1. There is no limitation on the number of (different) layers the delivery wall 300 may have.

[0078] One of the layers of the delivery wall 300 is a retention layer 320. This shows exemplarily FIG. 1. The retention layer 320 is adapted to be opened upon interaction with opening elements of a beverage production machine under the effect of rising pressure of the fluid being injected in the capsule 100. The retention layer 320 may be a film, membrane or ply with a defined thickness and preferably with a substantially planar surface.

[0079] The retention layer 320 is made of biodegradable material. Preferably, the retention layer 320 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also. Additionally or alternatively, the (material of the) retention layer 320 may have a defined fibre structure, such as a closed fibre structure. For example, the retention layer 320 material may be a fibre structure with at least 50% of weight corresponding to softwood pulp. Further examples for the material of the retention layer 320 may be one or any combination of the group of cellulose fibres, paper, biopolyesters, PHA, PHB and co-polymers, PBS, PBS-A, PVOH and/or polymers where at least one of the monomer units is vinyl alcohol.

[0080] The retention layer 320 may be provided such that it is resilient against a built-up pressure in the chamber 250, preferably between 1 and 20 bar, more preferred between 10 and 20 bar, most preferred between 12 and 18 bar. In particular, the material of the retention layer 320 may be configured such that it is resilient against a built-up pressure in the chamber 250 within such pressure ranges. Therein, the thickness and density of the material may influence the stiffness, i.e. the resistance to a bend, of the retention layer 320. The retention layer 320 may have a thickness of material of 10 to 150 micrometres, preferably 30 to 70 micrometres. Alternatively or additionally, the retention layer 320 may have a grammage between 20 and 150 g/m.sup.2, preferably between 40 and 100 g/m.sup.2. Preferably, the retention layer 320 may be attached to the (rim portion 211) capsule body 200, preferably by heat-sealing or adhesive bonding.

[0081] FIG. 4 shows exemplary pressure curves of paper-based materials that may be suitable for being used for the retention layer 320. From FIG. 4 it can be seen that a paper-based material offers at least for a time interval of around 15 seconds a resistance against pressures of up to 17 bar, thereby blocking fluids under pressure and thus, making it suitable as a layer of the delivery wall 300 for beverage preparation.

[0082] Another layer of the delivery wall 300 is a filter layer 310 as FIG. 1 exemplarily shows. The filter layer 310 may be configured to filter out particles from the prepared beverage before dispensing the same via (from) the delivery wall 300. The filter layer 310 may be a film, membrane or ply of a defined thickness (and/or with a (largely) planar surface).

[0083] The filter layer 310 is made of biodegradable material. Preferably, the filter layer 310 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also. For example, the filter layer 310 may be a non-woven material, such as cellulose fibres or PLA. Further examples may be cellulose fibres, wood pulp, sugarcane pulp, rayon fibres, PBS, PBS-A, PHB and/or PLA.

[0084] The mechanical and filtering properties of the filter layer 310 may be influenced by the thickness of the material, its density as well as its permeability for particles. The filter layer 310 may have a thickness of material of 10 to 300 micrometres, preferably 30 to 250 micrometres. Additionally or alternatively, the filter layer 310 may have a grammage between 10 and 200 g/m.sup.2, preferably between 20 and 150 g/m.sup.2.

[0085] FIG. 5 shows exemplarily pressure curves of various non-woven materials that may be used for the filter layer 320. It can be taken from FIG. 5 that non-woven materials show pressure resistance of up to 2.5 bar for a time span below 10 seconds. Considering typical conditions of the beverage preparation process, this pressure resistance appears to be relatively limited and short.

[0086] However, the present invention provides a solution, by which a particular arrangement and combination of different types of materials, such as shown exemplarily in the aforementioned FIGS. 4 and 5, leads to advantageous effects.

[0087] Therein, the retention layer 320 and the filter layer 310 are provided on the capsule body 200 such that the filter layer 310 is provided opposite to the chamber 250 with respect to the retention layer 320.

[0088] Preferably, the retention layer 320 may face the chamber 250. Alternatively or additionally, the retention layer 320 may be provided closer to the chamber 250 than the filter layer 310. This is exemplarily illustrated in FIG. 1.

[0089] Preferably, the retention layer 320 may at least partially, preferably completely, cover the opening 230. An adhesive layer may be provided between the retention layer 320 and the capsule body 200 (or the rim portion 211) that may completely cover the surface of the retention layer 320 being directed towards the container body 200. The filter layer 310 may at least partially cover the retention layer 320. Preferably, the filter layer 310 may be provided flush with the retention layer 320 in a circumferential direction (and/or preferably with the perimeter of the capsule body 200). The retention layer 320 and the filter layer 310 may be joined to each other at least partially on sides that face each other, preferably by adhesive bonding or heat-sealing. Therein, an adhesive layer may preferably be provided between the retention layer 320 and the filter layer 310 that is of a biodegradable and preferably compostable material, such as vegetable based starch or acrylic adhesive. Preferably, the retention layer 320 and the filter layer 310 may form a substantially even surface on one end of the capsule 100. For example, the retention layer 320 and the filter layer 310 may be joined to each other by e.g. heat-bonding such that the adhesive layer is provided as a stripe that covers only part of the surface of each of these two layers 310, 320. For example, the stripe may be provided along the perimeters of these two layers 310, 320. However, this is only an example and not to be considered as a complete enumeration. Instead, for example, the adhesive layer may also be provided in the centre of overlap between these two layers 310, 320.

[0090] Preferably, each of the filter layer 310 and the retention layer 320 may be made of a different biodegradable and preferably also compostable material. The different materials of the two layers may distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fibre structure and/or fibre orientation. For example, it may be preferred that the elasticity of the filter layer 310 may be higher than the elasticity of the retention layer 320, as, as typical for layered structures, layers being further away from the base layer undergo larger strain during bending compared to layers being closer thereto.

[0091] With such arrangements, a pressure curve as exemplarily illustrated in FIG. 2 can be achieved. As becomes immediately clear from FIG. 2, the corresponding pressure curve of the capsule 100 is highly advantageous for preparing a beverage.

[0092] FIG. 3 shows a comparison between the pressure curves of two capsules that comprise identical components and identical materials. However, capsule n° 1 does not use the arrangement of the invention for forming its delivery wall while capsule n° 2 has the configuration of the capsule 100 of the invention. As can be seen, the pressure resistance of the capsule 100 (capsule n° 2) as well as its pressure stability during the time of extraction is significantly more stable and improved than the pressure resistance and pressure stability of the other capsule (capsule n° 1) for beverage preparation applications.

[0093] Preferably, the filter layer 310 and/or the retention layer 320 may be made of a different material than the protective layer 400. To provide also the delivery wall 300 with a barrier against oxygen or moisture, it is conceivable that the retention layer 320 (and/or the material of the retention layer 320) may be configured such that it provides a bidirectional barrier against liquid and/or gaseous substances entering or leaving the chamber 250. The delivery wall 300 may comprise additional layers beside the filter layer 310 and the retention layer 320. The protective layer 400 may form part of the delivery wall 300.

[0094] A further aspect of the present invention relates to a process for manufacturing the above-described capsule 100.

[0095] Therein, the capsule body 200 is formed from a biodegradable pulp material, such as cellulose pulp, bamboo pulp, bagasse pulp or wood pulp. The injection wall 220 is formed (preferably along with the capsule body 200) such that at least a part of the chamber 250 for receiving the substance 500 for the preparation of the beverage is formed. The delivery wall 300 is provided and attached to the capsule body 200, e.g. by heat sealing. Therein, the delivery wall 300 is provided on the capsule body 200 such that the filter layer 310 is provided opposite to the chamber 250 with respect to the retention layer 320.

[0096] Preferably, the capsule body 200 may be formed by wet pulp moulding. Therein, a slurry of biodegradable pulp material, such as wood pulp, bagasse pulp, non-wood pulp, and/or cellulose based pulp in any form, may be pressed into a mould to form the capsule body 200. Thereafter, the so formed capsule body 200 is dried. At least a part of the inside surface (prior to filling) or at least a part of the outside surface of the capsule body 200 may be provided with the protective layer 400, e.g. by thermoforming.

[0097] Alternatively, the capsule body 200 may be formed by dry pulp moulding. Therefore, a blank of preferably dried cellulose fibres may be provided, from which the capsule body 200 is formed with a tool preferably under the application of heat and/or water. The protective layer 400 may be applied as a liner on the inside of the capsule body 200 (for example by applying heat and/or a vacuum), which may extend on and cover the inwards facing surface of the sidewall 210 between both ends of the capsule body 200 and may extend and cover the rim portion 211 on its surface facing away from the chamber 250.

[0098] In both of the two aforementioned processes, the injection wall 220 may be formed along with the capsule body 200, e.g. in the same step. Preferably, the injection wall 220 may be formed either by (wet/dry) pulp moulding or by attachment, e.g. with a biodegradable adhesive, of a membrane or film as the injection wall 220 to the capsule body 200 after forming of the capsule body 200. For example, by (wet/dry) pulp moulding the injection wall 220 may be formed together with the capsule body 200 in the same process step while a second, separate process step may be needed for attaching the injection wall 220 with an adhesive. The capsule body 200 may be filled with the substance 500 for the preparation of the beverage. The delivery wall 300 may be provided and attached to the capsule body 200 such that the retention layer 320 may face (be directed towards) the chamber 250. The protective layer 400 may be added to a (circumferential) surface of the capsule 100, which is preferably made from a biodegradable and/or compostable material. At least a part of an inner facing or of an outer facing surface of the injection wall 220 (a surface which in addition may delimit the chamber 250) may be provided with the protective layer 400.

[0099] A further aspect of the invention relates to a use of the above-described capsule 100 for preparing a beverage in a beverage production machine having a capsule holder. For example, the capsule 100 as described above may be provided and inserted in a beverage production machine. Preferably, the capsule 100 is placed such in the beverage production machine that the filter layer 310 is closer to (and eventually contacts) the opening elements of the machine than the retention layer 320. The injection wall 220 of the capsule 100 may be perforated by an injection nozzle of the beverage production machine to inject a fluid in the chamber 250. The fluid, such as a liquid or a liquid/gas mixture, may be injected into the chamber 250, thereby causing a pressure to build up in the capsule 100 and the delivery wall 300 is to thrust against opening elements, e.g. of the beverage production machine. At least part of the delivery wall 300 may be perforated by the opening elements when the pressure of the injected fluid reaches a predetermined level in the chamber 250. Preferably, the retention layer 320 may be perforated. Alternatively or additionally, the delivery wall 300 may be provided such (e.g. with regards to its material configuration/selection) that the retention layer 320 may be perforated while the filter layer 310 is not perforated. The prepared beverage may be drained from the capsule 100, wherein the beverage may pass through openings in the retention layer 320 and (cavities in the porous material of) the filter layer 310, wherein the retention layer 320 may be closer to the chamber 250 than the filter layer 310 and the filter layer 310 is provided opposite to the chamber 250 with respect to the retention layer 320.

[0100] The invention is not limited by the embodiments as described hereinabove, as long as being covered by the appended claims. All the features of the embodiments described hereinabove can be combined in any possible way and be provided interchangeably. For example, the above-described order of the steps of the manufacturing process for the capsule 100 may be changed arbitrarily.