Capsules and a method for producing said capsules

Abstract

This invention relates to a capsule for preparing a beverage, the capsule comprising: - a generally rigid capsule body having circumferential sidewalls extending around an internal space of the capsule, the internal space being at least partially filled with beverage ingredients suitable for preparing the beverage; - a base wall covering the internal space at a first end of the sidewalls; - a flange circumferentially arranged around an opening side of the capsule at a second end of the sidewalls of the base body opposite to the base wall; - a cap covering the internal space and the opening side of the capsule at the second end of the sidewalls opposite to the base wall and tightly sealing the capsule, the cap being removably attached to the flange of the capsule; - a filter element positioned within the internal space of the capsule between the beverage ingredients and the cap; and - a carrier tray disposed within the internal space of the capsule between the cap and the filter, the carrier tray including a plurality of pre-formed outlet openings adapted to allow the prepared beverage to flow from the internal space out of the capsule when the capsule is used in the beverage preparation apparatus. According to the present invention, the capsule includes at least one mechanically deformable portion at or near the junction of the flange and the sidewall of the capsule, the mechanically deformable portion retaining the support plate within the internal space of the capsule. The present invention also relates to a method for manufacturing the capsule and the use of the capsule.

Description

Technical Field

[0001] This invention relates to a capsule integrated with a filter element for preparing beverages, preferably crema-free coffee, tea, milk, or chocolate-based beverages.

[0002] The capsule comprises a generally rigid capsule body having circumferential sidewalls, a base wall, and a cap. The circumferential sidewalls extend around an internal space of the capsule, which is at least partially filled with beverage ingredients for preparing the beverage (such as coffee). The base wall covers the internal space at a first end of the sidewall, and the cap covers the internal space at a second end of the sidewall opposite the base wall. The capsule integrates a filter and an aluminum disc including an opening within its internal space, and the cap is removably attached to the capsule.

[0003] The present invention also relates to a method for producing the capsules. Background Technology

[0004] Capsules used to prepare beverages in a beverage preparation apparatus and exhibit the aforementioned characteristics are generally known in the prior art. The beverage preparation apparatus includes a brewing chamber in which the capsule is positioned. Liquid from the beverage preparation apparatus is injected into the capsule to extract the beverage from extractable components (typically roasted and ground coffee or tea) contained within the capsule's internal space, or to prepare the beverage from soluble components (typically instant coffee, instant tea, or instant milk, or chocolate-based products).

[0005] In most capsules currently on the market, the internal space of the capsule is airtight or liquid-tight to protect it from environmental influences before it is used in beverage preparation equipment, so as to maintain or prolong the freshness of the beverage ingredients during storage.

[0006] Capsules to date typically comprise a generally rigid capsule body having circumferential sidewalls extending around an internal space and a base wall covering the internal space at a first end of the sidewalls. At a second end of the sidewalls opposite the base wall, the capsule body has an open-fill side. Liquid-tight and gas-tight caps (e.g., aluminum caps) are positioned above the open-fill side of the capsule body to cover the internal space. In use, it is preferable to puncture the capsule at the base wall and / or the cap to form an injection opening for injecting a liquid (such as hot water) and / or an outlet opening allowing the prepared beverage to escape from the capsule.

[0007] More specifically, known capsules are conceived for use in beverage preparation devices that deliver pressurized hot water to prepare espresso-type beverages, wherein the pressurized hot water is injected into the capsule to cause the extraction of substances from coffee beverage components, and wherein the foam formed on the beverage corresponds to an espresso beverage with a crema layer obtained by a known piston-type espresso machine using high-pressure brewing.

[0008] For coffee beverages without crema, such as non-foamed coffee beverages, also known as filtered coffee, specific equipment is typically used where the beverage is prepared by non-pressurized filtration of a mixture of beverage ingredients and water.

[0009] It has been proposed to use some capsules intended for use in pressurized beverage devices for the preparation of crimson-free coffee.

[0010] EP 2952125 A1 discloses a capsule for preparing a beverage using an extractable product contained within its internal space. The capsule includes a circumferential first wall; a second wall that closes the circumferential first wall at a first end; and a flexible, sheet-like perforated and / or porous third wall that closes the circumferential first wall at a second open end opposite the second wall, thereby forming the internal space. The third wall forms the outermost boundary of the capsule in its axial direction and includes a woven or nonwoven filter material, such as filter paper.

[0011] WO 2019 / 013623 A1 discloses a capsule comprising a rigid capsule body having a circumferential wall and a base wall defining an internal space filled with beverage ingredients. The capsule has a cap of liquid-tight material covering the open-fill side of the circumferential wall opposite the base wall. The cap has a pre-formed outlet opening adapted to allow the prepared beverage to flow out of the internal space when the capsule is used in a beverage preparation apparatus. The outlet opening is liquid-tightly closed by a removable covering element extending above at least a portion of the cap.

[0012] However, these solutions are not entirely satisfactory in terms of capsule construction, ergonomic use by consumers, and results in the cup.

[0013] Therefore, one object of the proposed invention is to provide a capsule with a simple construction for producing a filter-type coffee beverage without crema and a corresponding manufacturing method, which has all the characteristics of filter coffee made with a drip coffee maker and meets the desired sensory results in the cup as expected by consumers. Summary of the Invention

[0014] Therefore, the present invention provides a capsule for providing crema-free coffee, tea, milk or chocolate-based beverages.

[0015] This capsule is intended for use in the preparation of beverages and includes:

[0016] - A generally rigid capsule body having circumferential sidewalls extending around an internal space of the capsule, the internal space being at least partially filled with beverage ingredients suitable for preparing the beverage;

[0017] - Rigid base wall, which is integral with the capsule body, and the base wall covers the internal space at the first end of the side wall;

[0018] - A flange, which is arranged circumferentially around the opening side of the capsule at the second end of the sidewall of the base body opposite to the base wall;

[0019] - A cap that covers the interior space and the opening side of the capsule at the second end of the sidewall opposite to the base wall and tightly seals the capsule. The cap is removably attached to the flange of the capsule.

[0020] - A filter element positioned within the internal space of the capsule between the beverage ingredients and the cap; and

[0021] - A carrier tray disposed within the internal space of the capsule between the cap and the filter, the carrier tray including a plurality of pre-formed outlet openings adapted to allow the prepared beverage to flow out of the capsule from the internal space when the capsule is used in the beverage preparation apparatus.

[0022] According to the present invention, the capsule includes at least one mechanically deformable portion at or near the junction of the flange and the sidewall of the capsule, the mechanically deformable portion holding the support plate within the internal space of the capsule.

[0023] In the example where the capsule contains roasted and ground coffee as a beverage ingredient, the capsule’s specific structure allows for the production of coffee with limited foam and cream after the cap is removed during extraction in beverage preparation.

[0024] This freshly brewed coffee possesses the main characteristics of filter-brewed coffee, with very little crimson that disappears quickly, leaving only a ring of crimson around the rim of the cup. The result is a coffee with low body, very low acidity, and minimal bitterness, yet it is aromatic, smooth, and sweet.

[0025] Due to its specific construction, when the cap is removed to extract the capsule, the carrier disc and the filter are simultaneously retained within the capsule. Similarly, during and after capsule extraction in the beverage preparation machine (once the cap has been removed), the capsule maintains its integrity, and no coffee (wet coffee) powder escapes from the capsule.

[0026] Due to the proposed invention, in the capsule according to the invention, the carrier disc is positioned inside the capsule and maintains a distance between 0.1 mm and 2 mm from the cap. This allows for the avoidance of possible interaction between the carrier disc and the tearing surface of the extraction plate of the beverage preparation device when the coffee powder volume expands during extraction.

[0027] In fact, the capsules should maintain the extraction of beverage components at a pressure below 8 bar, more preferably below 5 bar.

[0028] In the proposed capsule structure, the filter element includes a nonwoven material layer adapted to prevent the outflowing coffee from passing through and to reduce the formation of a crema layer.

[0029] In the currently envisioned solution, the filter is positioned on the carrier plate. This facilitates the capsule assembly process. Furthermore, the filter can be secured to the carrier plate.

[0030] The capsule's cap includes a free pull tab that protrudes from it. The pull tab is integrated with the cap, allowing the entire cap to be removed. This makes handling and opening much easier.

[0031] In one proposed embodiment, the cap includes at least one aluminum layer to ensure a better shelf life for the coffee in the capsule.

[0032] In addition, the cap may include a plastic layer and / or a heat-sealing layer to ensure food-grade compatibility, thereby sealing the cap to the flange of the capsule.

[0033] Preferably, the carrier disc is made of aluminum, which allows for easy recycling in a conventional aluminum stream when the capsule is made of aluminum.

[0034] Preferably, the capsule body, cap, and carrier tray are all primarily made of aluminum. The use of aluminum ensures better coffee protection and a longer shelf life. Additionally, the capsules are easier to end their lifespan and easier to recycle.

[0035] In an alternative approach, the capsule body, cap, and carrier plate can each be made of plastic or of laminated or multilayered plastic components.

[0036] The proposed capsule contains a beverage ingredient. The beverage ingredient is preferably ground coffee, preferably in an amount of at least 4g, and more preferably between 4.5g and 15g.

[0037] In the proposed embodiment of the present invention, at least one mechanically deformable part is provided on the open side of the capsule opposite to the base wall, at or near the junction of the capsule flange and the side wall.

[0038] In another proposed embodiment of the invention, at least one mechanically deformable portion is provided on the side of the capsule opposite to the opening side of the capsule, at or near the junction of the capsule flange and the sidewall.

[0039] According to the invention, at least one mechanical deformation portion at the junction of the capsule flange and the sidewall is a deformation portion generated by crimping. This crimping deformation portion, generated by reducing the diameter (of the opening on the opening side of the capsule), allows the carrier disc to be retained inside the capsule by deforming the capsule (made of ductile material).

[0040] In order to hold the carrier disc fully and effectively inside the capsule, the number of mechanical deformation points (also known as crimp points) is between 2 and 10.

[0041] The mechanically deformable portions are distributed at an angle at the junction of the flange and the sidewall of the capsule, and preferably, the mechanically deformable portions are evenly distributed at the junction of the flange and the sidewall of the capsule.

[0042] The mechanically deformable part has a circular rolled edge mark (or shape) to avoid creating holes in the aluminum layer of the capsule.

[0043] The present invention also provides a method for manufacturing capsules according to the invention suitable for preparing beverages.

[0044] The proposed method for manufacturing includes the following steps:

[0045] - Provides a generally rigid capsule body, a rigid base wall, and a flange, the capsule body having circumferential sidewalls extending around an internal space to be at least partially filled with beverage ingredients suitable for preparing a beverage, the rigid base wall being integral with the capsule body and covering the internal space at a first end of the circumferential wall, and the flange being circumferentially arranged around the opening side of the capsule at a second end of the sidewall of the base body opposite to the base wall;

[0046] - The internal space is filled with a certain amount of the beverage ingredients through the opening side of the capsule body opposite the base wall;

[0047] - After the internal space is filled with the beverage ingredients, the filter is inserted into the internal space through the opening side of the capsule body;

[0048] - A carrier tray is inserted above the filter in the internal space through the opening side of the capsule body. Optionally, the filter and the carrier tray are inserted into the internal space of the capsule simultaneously. The carrier tray includes multiple outlet openings through which the beverage prepared in use can flow out of the capsule.

[0049] - The capsule is closed by attaching a cap, including a pull tab, to the flange of the capsule flange extending on the opening side, thereby tightly sealing the capsule.

[0050] According to the present invention, the manufacturing method further includes the step of forming a mechanically deformable portion of the capsule at or near the junction of the flange and the sidewall of the capsule, the mechanically deformable portion holding the carrier plate within the internal space of the capsule.

[0051] The proposed manufacturing method can be easily implemented in a conventional capsule production line with no significant changes other than inserting a new machine or module for inserting filters and carrier trays and crimping capsules.

[0052] The step of forming a mechanically deformable portion at the junction of the flange and sidewall of the capsule is performed before the step of sealing the open side of the capsule with the cap. This method eliminates the risk of puncturing the cap during the crimping process, and ensures complete product tightness once the cap is assembled.

[0053] In an alternative embodiment, the step of forming a mechanically deformable portion at the junction of the flange and the sidewall of the capsule is performed after the step of closing the open side of the capsule with a cap.

[0054] The step of forming a mechanically deformable part at the junction of the flange and the sidewall of the capsule is performed on the open side of the capsule opposite to the base wall.

[0055] In an alternative embodiment, the step of forming a mechanically deformable portion at the junction of the flange and the sidewall of the capsule is performed on the side of the capsule opposite to the opening side of the capsule.

[0056] The step of forming a mechanically deformable portion at the junction of the flange and sidewall of the capsule is performed using a crimping method. The advantage of this method is that the sidewall will deform without creating any opening / puncture area.

[0057] The step of forming a mechanically deformable portion at the junction of the flange and the sidewall of the capsule is performed using at least one crimping pin.

[0058] The at least one rolled pin has a rounded end shape to avoid piercing the sidewall of the capsule.

[0059] According to the invention, during the step of forming a mechanically deformable portion of the capsule at the junction of the capsule flange and the sidewall, the capsule deforms at at least two points, preferably three to ten points. A solution with eight crimping points was tested and verified to strike a balance between a truly good fixing disc and the ease of manufacturing crimping tools.

[0060] The mechanically deformable portions are distributed at an angle at the junction of the flange and sidewall of the capsule, preferably evenly distributed. It is advantageous to cover the entire disc surface to evenly distribute the retaining force. This provides optimal fixation of the disc within the capsule.

[0061] Specific embodiments of the invention are described below. These objectives are achieved by the invention, namely, the capsule, the system, and the method of capsule manufacturing. Attached Figure Description

[0062] The invention is further described with reference to the following examples and accompanying drawings, which form part of this invention. Unless clearly and explicitly indicated, the drawings are not intended to limit the scope of the invention in any way. It should be understood that the invention is not intended to be limited in any way to these exemplary embodiments and illustrations.

[0063] Note that the accompanying drawings are merely schematic diagrams illustrating embodiments of the invention by way of non-limiting example.

[0064] Embodiments of the present invention will now be described by way of example with reference to the following accompanying drawings, in which:

[0065] - Figure 1a is a perspective side view of a capsule tightly sealed before use in a beverage preparation apparatus according to the present invention;

[0066] - Figure 1b is a perspective side view of the capsule according to the invention, wherein the cap is partially removed;

[0067] - Figure 1c is a perspective side view of a capsule according to the present invention, wherein the cap has been removed and it is ready for use in a beverage preparation apparatus;

[0068] - Figure 2a is a schematic cross-sectional view of a capsule according to a first embodiment of the present invention;

[0069] - Figure 2b is an enlarged view of the bottom portion of the capsule shown in Figure 2a;

[0070] - Figure 2c is a view of the carrier plate of the capsule in Figure 2a before it is assembled into the capsule;

[0071] - Figure 3a is a schematic cross-sectional view of a capsule according to a second embodiment of the present invention;

[0072] - Figure 3b is an enlarged view of the bottom portion of the capsule shown in Figure 3a;

[0073] - Figure 4a is a schematic diagram of the carrier plate of the capsule of Figure 2a, according to the proposed first embodiment, once assembled in the capsule having 4 rolled edges.

[0074] - Figure 4b is a schematic diagram of the carrier plate of the capsule of Figure 2a, according to the proposed first embodiment, once assembled in the capsule having 8 rolled edges;

[0075] Figures 5a and 5b are schematic diagrams of the proposed process for assembling the carrier disk into the capsule according to the first and second embodiments.

[0076] - Figure 6a is an enlarged view of the identified bottom portion of the capsule according to a third embodiment of the present invention;

[0077] - Figure 6b is a schematic diagram of the proposed process for assembling the carrier disk into the capsule according to the proposed third embodiment;

[0078] - Figure 7 This is a schematic diagram of the proposed process for assembling the carrier plate into the capsule, according to an alternative embodiment. Detailed Implementation

[0079] As used in this specification, the words “including,” “contains,” and similar terms should not be construed as having an exclusive or exhaustive meaning. In other words, these terms are intended to mean “including but not limited to.”

[0080] Any references to prior art documents in this specification should not be construed as an admission that such prior art is well-known or constitutes part of common general knowledge in the art.

[0081] Figure 1a shows a capsule 1 before use in a beverage preparation apparatus according to the invention (defined as a storage state). Referring to Figure 2, the capsule 1 of Figure 1a includes a rigid capsule body 2. The body 2 includes a truncated conical sidewall 2a extending circumferentially around an internal space of the body. The capsule also includes a base wall 3 integral with the capsule body 2, which closes the internal space at a first end of the sidewall of the capsule body 2. A flange 4 extends radially outward from a second end of the sidewall of the capsule body 2a. At the second end of the sidewall, the capsule body 2 has an open-fill side.

[0082] Typically, the capsule body 2 is processed to food grade and, in most cases, includes a lacquer layer or polymer film layer applied to the inside of the capsule body.

[0083] The capsule also includes a flange 4 attached to the capsule body to seal the capsule cap 5. The cap 5 can be manually removed from the capsule by pulling a pull tab 6. In this case, the pull tab 6 is integrated with the cap 5, but alternative solutions can also be used.

[0084] The cover 5 is a flexible sheet foil made of aluminum, with an optional lacquer or polymer layer on the sealing side.

[0085] When the cover 5 includes a paint layer on its sealing side, the thickness of the paint layer may be from 0.003 mm to 0.03 mm. When the cover 5 includes a polymer layer on its sealing side, the thickness of the polymer layer may be from 0.01 mm to 0.05 mm.

[0086] The cap 5, designed for removal using a pull tab, is attached to the flange 4 using an adhesive layer. The adhesive is applied in the form of an adhesive layer and can be, for example, a heat-sealing varnish layer or a polymer film layer.

[0087] For example, the sealing layer forming the adhesive material can be a layer between 0.003 mm and 0.03 mm.

[0088] The adhesive layer allows the cap 5 to be removed from the flange 4 of the capsule without causing any damage to the capsule 1.

[0089] Before sealing the capsule, the interior space is filled with beverage ingredients. In this case, the capsule is filled with coffee powder (from roasted and ground coffee) before tightly sealing it with the cap to maintain the freshness of the coffee. Depending on the capsule size, the weight of the coffee ranges from 4g to 15g. However, tea, milk, or chocolate ingredients can also be considered.

[0090] The capsule in Figure 1b shows the capsule of Figure 1a, with the cap 5 partially removed by tearing open the pull tab 6, and the same capsule is shown in Figure 1c, with the cap 5 completely removed. As shown, the second end (filled side) of the capsule is no longer closed, and a membrane defining a carrier disc 7 is presented on the inner side of the capsule. The carrier disc 7 includes multiple pre-formed outlet openings 8 for the beverage (here, coffee) prepared in the beverage preparation apparatus. The capsule also includes mechanical deformation sections 11a, 11b, 11c… at the junction between the sidewall 2a and the flange 4, which hold the carrier disc 7 within the internal space of the capsule. Four mechanical deformation sections 11 are visible in Figure 1b. These mechanical deformation sections 11a, 11b, 11c… are also visible on the capsule of Figure 1c, and in fact, eight mechanical deformation sections can be observed. Their function and implementation will be explained in conjunction with Figure 2a and below.

[0091] The pre-formed outlet opening 8 of the carrier tray 7 is covered by the capsule cap 5, thereby sealing the capsule to maintain an airtight seal of the internal space of the capsule, thus ensuring the freshness of the beverage ingredients inside the capsule during storage.

[0092] As can be seen in cross-sectional views of various embodiments of the capsule of the present invention (e.g., see Figure 2a), the capsule also includes a filter element 9 positioned between the coffee powder and the carrier tray 7 within its internal space. The filter element 9 prevents solid particles of the beverage ingredients (e.g., coffee particles or tea leaves) from flowing out of the capsule and into the end consumer's cup during extraction.

[0093] In the proposed invention, both the capsule body 2 and the cap 5 are made primarily of aluminum.

[0094] However, other materials can be envisioned for the capsule body and lid.

[0095] For example, the capsule body and cap can be made of a plastic polymer material, or the capsule body and cap can be made of a paper-based material.

[0096] As understood, the capsules of this invention are used in accordance with conventional methods. A conventional high-pressure beverage preparation apparatus compatible with coffee capsules is used for extraction. The apparatus includes a fluid dispensing device and a brewing chamber. The fluid dispensing device is capable of feeding a certain amount of fluid (such as water) to the capsule at a pressure between 0.1 bar and 20 bar. The brewing chamber includes a first component for holding the capsule and a second component for closing the chamber. The second component includes an extraction plate with a tear-away surface for engaging the capsule at its second end opposite its base wall.

[0097] The typical extraction process of a sealed capsule in a beverage preparation device can be summarized as follows: The capsule is inserted into the brewing chamber of the beverage preparation device. A fluid distribution device feeds a certain amount of fluid (such as water) into the capsule through the inner base wall 3 to saturate the coffee and then proceed with extraction. As the pressure inside the capsule increases, the capsule cap comes into contact with the tear-open surface of the extraction plate, and the cap is altered by the tear-open surface to create an opening that allows coffee to flow out of the capsule.

[0098] The interaction between the lid and the tear-off surface creates an outlet opening on the lid surface for the coffee to flow out, which participates in the formation of foam and cream during the preparation process.

[0099] The use of conventional capsules (closed capsules) in the above process results in coffee extraction at a pressure between 8 bar and 20 bar.

[0100] In the extraction process of the capsule of the present invention, the capsule cap is removed before the capsule is inserted into the brewing chamber of the beverage preparation device. A fluid dispensing device feeds a certain amount of fluid (such as water) into the capsule through the base wall 3 inside the capsule to saturate the coffee and then extract it. The extracted coffee passes through the filter element 9 and then flows out through the outlet opening of the carrier plate 7. During extraction, the carrier plate 7 (located at a certain distance from the flange of the capsule) does not contact the tearing surface of the extraction plate of the beverage preparation device, so that the carrier plate 7 is not changed by tearing during the extraction of the capsule.

[0101] Depending on the amount of coffee inside the capsule and the structure of the filter element, the use of the capsule of the present invention (in a conventional beverage preparation apparatus) results in coffee extraction at a pressure between 0.1 bar and 8 bar.

[0102] Since the cap is removed from the capsule before it is used in the beverage preparation apparatus and when the carrier plate is inside the capsule (see, for example, Figure 2a), there is no interaction between the carrier plate 7 and the tear-off surface of the extraction plate.

[0103] More specifically, when using the capsule 1 of the present invention to prepare coffee in a beverage preparation apparatus, the user removes the cap 5 by tearing open the pull tab 6 before inserting the capsule into the beverage preparation machine. The base wall 3 of the capsule body 2 is further pierced and opened by the piercing device of the beverage preparation apparatus to supply water into the capsule under pressure for preparing the coffee beverage.

[0104] Because the capsule is not sealed when used in a beverage preparation apparatus (cap 5 is removed and the outlet opening is accessible), the extraction pressure that accumulates inside the capsule is limited (0.1 bar to 6 bar), and the formation of foam and cream during extraction is limited.

[0105] Therefore, since no pressure buildup and sudden pressure drop occur due to the interaction between the coffee / lid / opening element and the tear-off surface of the extraction plate of the beverage preparation device (as with conventional capsules), the coffee obtained in the cup has very little or no crema.

[0106] The capsules of this invention allow for the preparation of crimson-free coffee, tea, milk, or chocolate based on the beverage ingredients inside the capsule.

[0107] Figure 2a illustrates a first embodiment of the capsule of the present invention. As disclosed, the capsule includes a carrier disk 7 within its internal space, the carrier disk including a plurality of pre-formed outlet openings 8.

[0108] As shown in Figure 2b (an enlarged sectional view of the bottom component portion identified in Figure 2a), the carrier plate 7 is positioned inside the capsule at a distance between 0.1 mm and 2 mm from the cover 5, and the cover 5 is sealed on the flange 4.

[0109] The gap between the capsule cap 5 (and thus the flange 4 once the cap is removed for extraction) and the carrier plate 7 provides a recess for the tear-off surface of the extraction plate of the beverage preparation device to protrude inside the capsule without contacting the carrier plate 7 and therefore without contacting the coffee in the capsule.

[0110] The carrier plate 7 is a substantially circular material piece as shown in Figure 2c, and its diameter is approximately the inner diameter of the capsule at the position of the carrier plate 7 in the positioning / insertion / holding (depending on the assembly process).

[0111] Therefore, in the proposed implementation, the diameter of the carrier disk 7 is approximately 29.5 mm and 30.5 mm.

[0112] In the proposed implementation, the carrier plate is made of aluminum. Its thickness is approximately 0.3 mm, but can vary between 0.1 mm and 1 mm.

[0113] In the proposed solution, the support disc 7 is held inside the capsule by a localized mechanical deformation 11 formed on the capsule at the junction between the sidewall 2a and the flange 4 of the capsule 1. In the detailed cross-section of Figure 2b, one such mechanical deformation 11 is visible. The mechanical deformation is in the form of a rolled edge point 11 and is located on the opening side of the capsule opposite the base wall 3.

[0114] Since the capsule is made of a ductile material, preferably aluminum, the mechanically deformed portion formed by the rolled edge allows for a reduction in diameter and thus retains the carrier disc 7 (and the filter) inside the capsule. The carrier disc is then held inside the capsule 1.

[0115] Here, during the manufacturing process, before sealing the capsule with the cap 5, a step is performed on the capsule to form a mechanically deformable portion at the junction of the flange 4 and the sidewall 2a, which leads to the crimping point 11.

[0116] At the junction of the flange and the sidewall of the capsule, there are rolled edge points 11 (also visible in Figure 1c) distributed at an angle on the periphery of the opening side of the capsule, that is, between 2 and 10 rolled edge points.

[0117] Considering the tools used to create the curled edges, the curled edges 11 will preferably be evenly distributed around the periphery of the opening side of the capsule.

[0118] In addition, depending on the curling tool used, the curling point 11 can have a circular curling mark.

[0119] In an alternative, the carrier disk 7 may be made of plastic or a laminate containing, for example, polyolefins (such as polypropylene, polyethylene, or any other semi-crystalline polymer). The carrier disk 7 may also be made of paper-based materials, such as coated paper, laminated paper, or molded paper.

[0120] As shown in Figure 2c, the pre-formed outlet opening 9 is a circular opening evenly distributed on the surface of the carrier plate. This uniform distribution of the outlet openings ensures a uniform flow rate of coffee exiting capsule 1. It also helps to prevent beverage (coffee powder clumps) from forming channels inside the capsule.

[0121] The diameter of the opening is set to approximately 0.75 mm to 1 mm, but the diameter can vary between 0.4 mm and 3 mm, and most preferably between 0.5 mm and 1.3 mm.

[0122] The number of preformed outlet openings can vary depending on the size of the capsule and the desired coffee delivery speed. In the disclosed embodiments, the carrier tray 7 includes between 50 and 150 openings, preferably about 90 openings, and in the presented embodiment, 92 openings.

[0123] In an alternative embodiment, the preformed outlet opening may be elliptical in shape.

[0124] As shown in the figure, the capsule also includes a filter element 9, which is positioned on the ingredient powder (e.g., coffee powder) after the capsule is filled during a possible assembly process, and a carrier plate 7 is positioned between the filter element and the cap 5.

[0125] As shown in the enlarged view of Figure 2b, when the capsule is inverted, the filter element 9 is located on the support plate 7. The filter element is then supported by the support plate 7 within the container. The filter remains flat inside the capsule and does not come into contact with the torn surface of the extraction plate of the beverage preparation device during extraction.

[0126] The use of a two-piece design allows for the use of non-sealed filter materials, which is beneficial for sustainability.

[0127] As proposed in this embodiment, the filter element 9 is circular (disc-shaped) and has a diameter smaller than that of the carrier disk 7, i.e., between 28 mm and 30.5 mm, and is typically 0.1 mm smaller than the carrier disk.

[0128] However, in an alternative embodiment, the diameter of the filter element 9 may be similar to the diameter of the carrier disc 7.

[0129] The filter element 9 is made of a nonwoven material that is suitable for preventing / inhibiting the outflowing coffee from passing through too slowly or too quickly during beverage extraction. The purpose is to avoid the formation of a crimson layer and to prevent the outflowing coffee from passing directly through the carrier tray to the cup.

[0130] The filter is preferably made of compostable and / or biodegradable materials, and may be made of cellulose-based materials having the following technical characteristics. For example, it may be a paper-based filter element.

[0131] The filter element 9 of the proposed embodiment has a thickness between 20 micrometers and 300 micrometers, an air permeability in the range of 100 l / m² / s to 5000 l / m² / s (according to ISO 9237), and a weight in the range of 5 g / m² to 600 g / m². For example, it can be a paper-based filter element.

[0132] Filter elements may include layers of nonwoven material that are attached to another filter layer in any known manner.

[0133] In the proposed embodiments of Figures 2a to 2c, the filter element 9 and the carrier plate 7 are independent components positioned relative to each other. However, they can be assembled together, for example, by gluing. This would then change the assembly process within the capsule, as the insertion of the filter and the carrier plate would be performed in a single step.

[0134] The proposed circular carrier disk 7 may have a conical shape on its periphery to fit (press-fit) into a capsule having a truncated conical shape. However, other alternative shapes and arrangements of the carrier disk within the capsule are conceivable.

[0135] Importantly, when the cap 5 is removed and the capsule 1 is extracted in the beverage preparation machine, the carrier plate 7 and the filter element 9 remain in place inside the capsule. Several assembly processes are conceivable, and these processes will be disclosed later in conjunction with the proposed embodiments of the capsule according to the invention.

[0136] In a further developed solution of the first embodiment of the invention shown in Figures 3a and 3b (details of Figure 3a), a second filter, for example made of a nonwoven material, is added inside the capsule. The second filter element is positioned on and can be fixed to the side of the support plate facing the lid (the coffee-opposite side directly facing the conical plate of the beverage preparation device) without contacting the lid.

[0137] The purpose of the second filter 10 is to allow the coffee to flow laterally while matching the perforations with the flat top surface of the truncated pyramid.

[0138] As mentioned above, the second filter element is made of nonwoven material; however, it can be made of any suitable element compatible with the desired function.

[0139] The second filter element may have the following dimensions, ranging from 28 mm to 30.5 mm.

[0140] In the proposed implementation, the second filter element is substantially circular, with a diameter slightly smaller than that of the carrier disc 7.

[0141] The assembly process and structure proposed in Figures 2a to 2c can still be applied to this further improved solution.

[0142] Figures 4a and 4b show the capsule of Figure 2a (viewed from the open side of the capsule), wherein the carrier plate 7 is inserted into the capsule of Figure 2a once assembled in the capsule, and has 4 and 8 rolled edges respectively before the open side of the capsule is closed by the attachment cap.

[0143] The number of curled edges (mechanical deformation parts) can vary between 2 and 10 to allow the carrier plate 7 (and the filter element 9 supported by the carrier plate) to be held fully and effectively inside the capsule 1.

[0144] The curled edges 11 are distributed at an angle around the periphery of the capsule's opening side at the junction between the capsule's sidewall 2a and the flange 4. Preferably, as presented herein, the curled edges are evenly distributed along the periphery of the capsule's opening side.

[0145] The tools currently in use have a rounded end shape during the step of forming the mechanically deformed portion of the capsule, thereby allowing for a curled edge with a substantially rounded curled edge mark.

[0146] Figures 5a and 5b schematically illustrate how the capsule forming mechanical deformation section according to Figure 2a can be performed.

[0147] Figure 5a shows the capsule 1 (in cross-section) with the carrier disc 7 inserted therein. A crimping tool (also called a clamping tool) 18, including two crimping pins 18a, is visible. Each crimping pin has a rounded end shape 19 and is positioned to be pressed from the open side of the capsule to the joint between the upper sidewall 2a of the capsule and the flange 4 to cause local deformation of the capsule body.

[0148] Figure 5b shows the same capsule after the mechanical deformation of the joint between the sidewall 2a and the flange 4 is formed by the crimping tool 18. It can be seen that the mechanical deformation on the capsule at this particular location has caused the crimping point 11, and for each mechanical deformation, a bead 20 has been generated (due to the physical transfer of material).

[0149] Since the beverage ingredients, filter element 9, and carrier plate 7 should remain in the capsule during the step of forming the mechanical deformation part of the capsule, this step is performed while the capsule is positioned so that its opening side is facing upward.

[0150] In this configuration, the formed beads 20 (also known as burrs) are located above the bearing disk 7.

[0151] When considering the capsules of Figures 2a and 2b, bead 20 is located below the support plate 7 and thus allows it to be held inside the capsule.

[0152] Depending on the number of crimping points 11 to be completed on the capsule, the crimping tool 18 will include between 2 and 10 crimping pins 18a. Therefore, the crimping tool will have crimping pins 18a distributed at an angle.

[0153] In Figures 5a and 5b, sealing devices 21 are present on the capsule. These sealing devices provide fluid-tight engagement with the sealing profile of the capsule engagement member of the beverage preparation machine, as disclosed, for example, in EP 1654966 B1.

[0154] As clearly seen in the figure, the sealing device 21 is not damaged during the formation of the mechanical deformation portion of the capsule and maintains the sealing function provided by the sealing device.

[0155] As disclosed, for example, in EP 2 303 077 B1 or EP 2 387 922 B1, the sealing function of the sealing device formed by the protrusions on the flange of the capsule and / or the deformed portion of the flange is maintained due to the specific position of the mechanically deformed portion.

[0156] To better understand the complete manufacturing process, the steps of the process ending with the capsule according to Figure 2a are given below.

[0157] First, a generally rigid capsule body 2 is provided, having circumferential sidewalls 2a extending around an internal space to be at least partially filled with beverage ingredients suitable for preparing a beverage. The capsule body can be manufactured by deep drawing aluminum foil, but other techniques exist depending on the material of the capsule body.

[0158] As previously described, the capsule body 2 includes a sidewall 2a, a base wall 3, and a flange 4 located on the opening side of the capsule opposite to the base wall.

[0159] Then, a certain amount of beverage ingredients is filled into the internal space through the opening side of the capsule. The amount of beverage ingredients depends on the type of beverage, coffee, tea, etc., but also on the range of beverages to be made (e.g., extended coffee).

[0160] Once the capsule is filled with beverage ingredients, the filter element 9 is inserted into the internal space through the opening side of the capsule body. Therefore, in the configuration of Figure 5a (with the opening side of the capsule pointing upwards), the filter element is inserted into the capsule on top of the beverage ingredients.

[0161] The carrier plate 7 is then inserted above the filter element 9 in the internal space through the opening side of the capsule body.

[0162] As already described in detail, the carrier tray 7 includes multiple outlet openings 8 through which beverages prepared in use can flow out of the capsule.

[0163] Alternatively, the filter element 9 and the carrier plate 7 can be inserted into the internal space of the capsule simultaneously. When inserted together, the two elements can be attached together or not.

[0164] Then, a step is performed to form a mechanically deformed portion (also defined as a crimp) at or near the junction of the flange and sidewall of the capsule, in order to retain the carrier disc within the internal space of the capsule, as previously explained. Due to the specific crimping tool 18 disclosed above, crimping can be performed simultaneously at several points: between 2 and 10 crimping points. Preferably, the crimping points are evenly distributed along the periphery of the capsule's opening side at the junction of the flange and sidewall of the capsule.

[0165] The capsule's opening side is further sealed by attaching cap 5. Various techniques can be used depending on the cap's material. In the case of aluminum leads (including lake-type leads), heat sealing can be used.

[0166] According to the proposed capsule, cap 5 includes a pull tongue 6.

[0167] Before using the capsule in a beverage preparation device, the tightly sealed cap of the capsule can be removed from the capsule.

[0168] The capsules are then removed from the production line and ready for use.

[0169] It should be noted that the sealing devices 21 are not damaged during the crimping step, so their associated sealing function is fully maintained.

[0170] In the above disclosure, the step of forming the mechanically deformable part of the capsule is performed before the step of closing the open side of the capsule with the cap. However, it is conceivable that the deformation step is performed after the open side of the capsule is closed with the cap.

[0171] As shown in Figures 6a and 6b, at the edge of the flange, i.e., at the junction between the sidewall 2a and the flange 4, at least one local mechanical deformation is made from the side of the capsule opposite to the opening side of the capsule, designed to retain the support plate 7 inside the capsule body. Here, the mechanical deformation is applied directly to one side of the sidewall 2a of the capsule body 2.

[0172] Similarly, as described in Figures 5a and 5b, a crimping tool 18, including at least one crimping pin 18a, is used to provide a mechanical deformation at a specific location on the capsule in order to retain the carrier disc 7 inside the capsule.

[0173] This variant can be performed before or after the cap 5 is positioned and / or sealed onto the capsule. When using this variant, the distance between the support disc 7 and the flange of the capsule body will be less than the distance when local deformation is made on the sidewall of the capsule body (but sufficient to avoid the interaction between the support disc and the cone position of the beverage device during extraction) (Figure 6b).

[0174] Figure 7A view is presented showing how the capsule forms a mechanically deformable part during the assembly process, wherein the capsule's support plate 7 is clamped inside the capsule body by the local deformation of the capsule from the outside of the capsule.

[0175] exist Figure 7 During assembly, once the carrier plate 7 (or carrier plate 7 plus filter element 9) is inserted into the capsule body 7, the crimping tool 18 presses down on the capsule body from the outside near the junction of the capsule flange and sidewall, just above the horizontal level of the carrier plate 7 when the carrier plate is positioned within the capsule's internal space, causing a local deformation 11 in the capsule body. Due to this local deformation, the carrier plate 7 remains in the proper position inside the capsule.

[0176] The outer side of the capsule body is locally deformed from the outside along the circumference of the capsule (e.g., every 90°). This is sufficient to ensure the effective retention of the support disc 7.

[0177] As shown in the figure, the step of locally forming a mechanically deformed portion of the capsule at the junction of the flange and the sidewall is performed using a crimping method. However, other methods for forming a mechanically deformed portion of the capsule at this particular location, such as stamping, metal drawing, and embossing, can be used.

[0178] The presented implementation schemes for the carrier disc and for the manufacturing and assembly process can be combined whenever needed and can improve the retention of the carrier disc 7 (with or without the filter element 9) inside the capsule body 2.

[0179] The proposed capsule can be associated with a sealing device located on the flange of the capsule, thereby ensuring a liquid-tight connection between the capsule and the injection component of the beverage production machine. For example, the sealing device could be a silicone ring applied to the base of the flange and the sidewall of the capsule body, or one or more protrusions or bridges formed on (and integral with) the flange. Such sealing devices (not shown) contribute to the liquid-tight arrangement with the beverage production machine.

[0180] Although the invention has been described by way of example, it should be understood that variations and modifications may be made without departing from the scope of the invention as defined in the claims. Furthermore, if known equivalents exist for specific features, such equivalents should be incorporated as expressly mentioned in this specification.

Claims

1. A capsule for preparing a beverage, said capsule comprising: - A rigid capsule body having circumferential sidewalls extending around an internal space of the capsule, the internal space being at least partially filled with beverage ingredients suitable for preparing the beverage; - Base wall, which covers the interior space at the first end of the side wall; - A flange, which is arranged circumferentially around the opening side of the capsule at the second end of the sidewall of the capsule body opposite to the base wall; - A cap, which covers the internal space of the capsule and the opening side at the second end of the sidewall opposite to the base wall and tightly seals the capsule, the cap being removably attached to the flange of the capsule; - A filter element, which is positioned within the internal space of the capsule between the beverage ingredients and the cap; and - A support tray disposed within the internal space of the capsule between the cap and the filter element, the support tray including a plurality of pre-formed outlet openings adapted to allow the prepared beverage to flow from the internal space out of the capsule when the capsule is used in a beverage preparation apparatus. The capsule is characterized in that it includes at least one mechanically deformable portion at or near the junction of the flange and the sidewall of the capsule, the mechanically deformable portion holding the support plate within the internal space of the capsule.

2. The capsule for preparing a beverage according to claim 1, wherein the at least one mechanically deformable portion at the junction of the flange and the sidewall of the capsule is located on the open side of the capsule opposite to the base wall.

3. The capsule for preparing a beverage according to claim 1, wherein the at least one mechanically deformable portion at the junction of the flange and the sidewall of the capsule is located on the side of the capsule opposite to the opening side of the capsule.

4. The capsule for preparing a beverage according to any one of claims 1 to 3, wherein the at least one mechanically deformed portion at the junction of the flange and the sidewall of the capsule is a deformed portion produced by edge curling.

5. The capsule for preparing a beverage according to any one of claims 1 to 3, wherein the number of mechanically deformable portions is at least two points.

6. A capsule for preparing a beverage according to any one of claims 1 to 3, wherein the mechanically deformable portion is distributed at an angle at the junction of the flange and the sidewall of the capsule.

7. The capsule for preparing a beverage according to claim 6, wherein the mechanically deformable portions are uniformly distributed at the junction of the flange and the sidewall of the capsule.

8. The capsule for preparing a beverage according to any one of claims 1 to 3, wherein the mechanically deformed portion has a circular rolled edge marking.

9. A capsule for preparing a beverage according to any one of claims 1 to 3, wherein the capsule body, the cap, and the carrier plate are all primarily made of aluminum.

10. The capsule for preparing a beverage according to any one of claims 1 to 3, wherein the cap includes a free pull tab protruding from the cap.

11. A method of manufacturing a capsule, said capsule being suitable for preparing a beverage, and being a capsule according to any one of claims 1 to 10, wherein said method comprises: - Provides a rigid capsule body, a base wall, and a flange, the capsule body having a circumferential sidewall extending around an internal space to be at least partially filled with beverage ingredients suitable for preparing the beverage, the base wall covering the internal space at a first end of the circumferential sidewall, and the flange being circumferentially arranged around the opening side of the capsule at a second end of the sidewall of the capsule body opposite to the base wall; - The internal space is filled with a certain amount of the beverage ingredients through the opening side of the capsule body opposite to the base wall; - After the internal space is filled with the beverage ingredients, a filter element is inserted into the internal space through the opening side of the capsule body; - A carrier tray is inserted above the filter element in the internal space through the opening side of the capsule body. The carrier tray includes a plurality of outlet openings through which beverages prepared in use can flow out of the capsule. - The capsule is closed by attaching a cap, including a pull tab, to the capsule flange extending on the opening side, thereby tightly sealing the capsule; The method is characterized by further comprising the step of forming a mechanically deformable portion at or near the junction of the flange and the sidewall of the capsule, the mechanically deformable portion holding the carrier plate within the internal space of the capsule.

12. The method of manufacturing a capsule according to claim 11, wherein the step of forming a mechanically deformable portion of the capsule at the junction of the flange and the sidewall is performed before the step of closing the open side of the capsule with a cap.

13. The method of manufacturing a capsule according to claim 11, wherein the step of forming a mechanically deformable portion of the capsule at the junction of the flange and the sidewall is performed after the step of closing the open side of the capsule with a cap.

14. The method of manufacturing a capsule according to any one of claims 11 to 13, wherein the step of forming a mechanically deformable portion of the capsule at the junction of the flange and the sidewall is performed on the opening side of the capsule opposite to the base wall.

15. The method of manufacturing a capsule according to any one of claims 11 to 13, wherein the step of forming a mechanically deformable portion of the capsule at the junction of the flange and the sidewall is performed on the side of the capsule opposite to the opening side of the capsule.

16. The method of manufacturing a capsule according to any one of claims 11 to 13, wherein the step of forming a mechanically deformable portion of the capsule at the junction of the flange and the sidewall is performed using a crimping method.

17. The method of manufacturing a capsule according to any one of claims 11 to 13, wherein the step of forming a mechanically deformable portion of the capsule at the junction of the flange and the sidewall is performed using at least one crimping pin.

18. The method of manufacturing a capsule according to claim 17, wherein the at least one crimp pin has a rounded end shape.

19. The method of manufacturing a capsule according to any one of claims 11 to 13, wherein during the step of forming a mechanically deformable portion of the capsule at the junction of the flange and the sidewall of the capsule, the capsule deforms at at least two points.

20. The method of manufacturing a capsule according to claim 19, wherein the mechanically deformable portions are distributed at an angle at the junction of the flange and the sidewall of the capsule.

21. Use of the capsule according to any one of claims 1 to 10 for the preparation of a beverage.

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