Cup and capsule for the preparation of a beverage

Abstract

The co-extruded cup (2) made of plastic according to the invention can be used to produce a capsule for the preparation of an infusion or soluble beverage. The cup (2) comprises an inlet opening (21) defined by an upper rim (4), a bottom (3) provided with an outlet opening (31) defined by a spout (32), and an inner seat (33) having a plurality of vertically protruding ridges. The cup (2) has a multi-layered wall (7) comprising an outer layer (71), an inner layer (73), and an intermediate gas barrier layer (72) extending from the upper rim (4) to the spout (32). The cup (21) is characterized in that the bottom (3) is free of radial reinforcing fins, and the intermediate layer (72) extends uniformly from the upper rim (4) to the spout (32) without interruption.

Description

TECHNICAL FIELD

[0001] The present invention relates to a cup, also known as a pod, made of plastic material, for the production of capsules for the preparation of infusion or soluble beverages. The present invention also relates to the capsule obtained by the cup, which can be used to package a predetermined dose and single dose of concentrated product (for example in the form of powder, granules, tablets) for the spontaneous preparation of beverages (such as tea, coffee, herbal tea, milk, chocolate beverage, etc.) by introducing a pressurized fluid (mainly hot water) inside the capsule itself. BACKGROUND

[0002] In the field of capsules or pods for coffee or other infusions, the use of "self-protected" or "barrier" capsules is known, i.e. which are able to guarantee the preservation of the organoleptic properties of the food substance contained therein, protecting it from external agents (such as gases, etc.) without the need to be packaged in a protective packaging such as an aluminum bag.

[0003] It is known in the art to make capsules using a cup (i.e. the capsule body containing the food substance to be infused or dissolved) obtained by injection molding of a polymeric material such as polybutylene terephthalate (PBT), which is known to provide high gas tightness in order to make the aroma of the mixture not to dissipate and to create an effective barrier against oxygen and humidity and guarantee a long shelf life of the product. However, some studies seem to highlight some drawbacks related to the use of this material, which are related to the risk of releasing toxic substances upon contact with boiling water.

[0004] Therefore, it is known in the art to produce capsules using a cup obtained by thermoforming a multilayer material having an intermediate barrier layer (for example ethylene vinyl alcohol (EVOH)) which protects the food substance from air, light and humidity. However, even this production technique has some drawbacks related to the non-constant and uneven distribution of the plastic material in the tortuous mold, which prevents the manufacture of articulated and complex geometries. In fact, thermoforming is not very suitable for making cups with complex geometries at the bottom, such as, for example, drip-proof labyrinthine portions or integrated opening devices.

[0005] Therefore, it is known in the art to use a cup having such a complex geometry integrally formed in the bottom, but to be manufactured by means of a co-extrusion process. This process involves the simultaneous injection into a mould cavity of several layers of different materials forming a multi-layer wall having in general an outer layer, an inner layer intended to be in contact with the food chamber and an intermediate layer of barrier type. Examples of these known cups are described in WO 2019 / 064096 Al of the present Applicant. The most complex aspect in the production of these co-extruded cups is the proper and uniform distribution of the intermediate barrier layer. Indeed, the complex geometry integrally formed in the bottom or the presence of radial reinforcing fins on the bottom create turbulences in the injection flow which have a detrimental effect on the distribution of the intermediate barrier layer. Indeed, the intermediate layer can have very thin areas or very thick areas or be bulging towards the outer or inner layer. All these very common situations involve a series of problems. For example, in the case of very thin areas, the ability of the intermediate layer to provide a proper barrier to oxygen is impaired. To overcome this deficiency which is considered as unacceptable in the art, the amount of barrier material injected into the mould is increased. However, since this material is the most expensive in the multi-layer, this alternative significantly increases the production cost of the cup and of the whole capsule. Moreover, very often, the non-uniformity of the intermediate barrier layer reaches the upper edge of the cup intended for the sealing lid. In these cases, a common defect is the surfacing of the barrier layer at the upper edge which destroys the sealing of the lid. This defect is also considered as unacceptable in the industry. SUMMARY

[0006] The object of the present application is to provide a cup for the production of a capsule for the preparation of an infusion or soluble beverage which solves the drawbacks of the prior art taking into account the needs of the industry.

[0007] In particular, the object of the present application is to provide a cup provided with a barrier and at the same time safe for health which allows to have a complex and engaging geometry necessary for the optimal dispensing of the beverage and at the same time has a proper and uniform distribution of the intermediate barrier layer.

[0008] This object is achieved by a cup made by co-injection moulding provided with a bottom geometry which guarantees a uniform distribution of the intermediate barrier layer up to the upper edge.

[0009] This object is achieved by a cup according to the present application and by a capsule obtained with said cup. BRIEF DESCRIPTION OF DRAWINGS

[0010] The features and advantages of the cup according to the present application will become clearer from the following description of a reference and non-limiting example, made with reference to the attached drawings, in which:

[0011] Figure 1 a cross-sectional view of an exemplary instance of a cup according to the present application, which cup is used as containing body of a capsule for the preparation of an infusion or soluble beverage according to the present application is shown; Figure 4A

[0012] Figure 2A and Figure 2B a bottom of a cup according to the present application in an exemplary instance is shown in external bottom view and in cross-sectional view, respectively;

[0013] Figure 3 an external bottom view of a bottom of a cup according to the present application in another exemplary instance is shown;

[0014] Figure 4A and Figure 4B a bottom of a cup according to the present application in yet another exemplary instance is shown in external bottom view and in cross-sectional view, respectively;

[0015] Figure 5 a cross-sectional view of an upper portion of a cup according to the present application is shown;

[0016] Figure 6A a non-uniform distribution of the intermediate barrier layer of a cup of the prior art provided with radial reinforcing fins is shown, Figure 6B a uniform distribution of the intermediate barrier layer of a cup according to the present application (in an exemplary instance of Figure 6A is shown in comparison; Figure 4A

[0017] Figure 7A and Figure 7B an upper portion of a cup of the prior art in Figure 6A is shown in comparison with an upper portion of a cup according to the present application in Figure 6B DETAILED DESCRIPTION

[0018] With reference to the drawings, reference number 2 indicates a cup which is adapted to define an internal volume V for containing at least one substance S, usually in powder or granular form, to be infused or dissolved. Said cup 2 can be used for producing a capsule for the preparation of an infusion or soluble beverage, indicated with reference number 1.

[0019] As shown in Figure 1 , the cup 2 is provided on one side with a bottom 3 and on the opposite side with an inlet opening 21 defined by an upper edge 4 which projects outwardly. The cup 2 is externally provided at the bottom 3 with an outlet opening 31 defined by a spout 32 which is adapted to allow the outflow of the infused beverage. The cup 2 is internally provided at the bottom 3 with an internal seat 33. ​​​

[0020] The base 33 is provided with a plurality of ridges 30, 90, 310, 360 which project vertically with respect to the base 33 itself towards the inside of the cup 2.

[0021] The base 33 comprises a central portion 310 defined by the ridges, which covers the outlet opening 31 of the nozzle 32.

[0022] The base 33 comprises an outer peripheral edge 360 defined by the ridges, on which the sealing disc 5 can be fixed.

[0023] Preferably, the base 33 comprises a plurality of supports 90 defined by the ridges, which are adapted to keep the disc 5 raised so that it does not obstruct the flow of beverage towards the nozzle 32.

[0024] In one embodiment, the upper surfaces of the ridges 30, 90, 310, 360 are substantially flat and devoid of cutting or piercing or tearing elements. In this exemplary example, the opening of the capsule 1 occurs by at least partial detachment of the disc 5 from the edge 360, or by bulging open of some portions of the disc 5 provided with suitable weakening.

[0025] In different exemplary examples, the upper surfaces of at least some of the plurality of ridges, for example of the plurality of supports 90, are provided with cutting or piercing or tearing profiles. In this exemplary example, the opening of the capsule 1 occurs by means of perforation of the disc 5 by means of the opening means represented by the supports 90.

[0026] Preferably, the base 33 comprises a labyrinth 30 formed by at least one ridge, which is adapted to prevent the passage of the infusion beverage towards the nozzle 32 by means of the capillary phenomenon when the pressure inside the capsule 1 falls below a threshold value, or to completely prevent the passage of the infusion beverage towards the nozzle when the capsule 1 is disengaged from the infusion group of the machine.

[0027] The cup 2 is made of plastic material by means of co-injection moulding, i.e. several layers of different material are injected simultaneously into a mould cavity and fill said cavity, thus forming a multi-layer wall 7. As Figure 4B illustrated, the cup 2 has a multi-layer wall 7 with an outer layer 71, an inner layer 73 intended to come into contact with the food chamber S and an intermediate layer 72 of barrier type. Advantageously, the intermediate layer 72 forms a barrier against gases, in particular oxygen.

[0028] As Figure 5 illustrated, the multi-layer wall 7 (and in particular the intermediate barrier layer 72) extends uninterruptedly from the upper edge 4 (excluding the upper edge) to the nozzle 32 (excluding the nozzle) and also to the inside of the inner base 33 and of the central pin 312.

[0029] Preferably, the intermediate layer is made of ethyl vinyl alcohol (EVOH) or polyvinyl alcohol (PVOH).

[0030] Preferably, both the outer layer and the inner layer are made of polypropylene (PP), or polyethylene (PE), or polylactic acid (PLA). Thus, the materials forming the inner layer 73 and the outer layer 71 are non-barrier materials belonging to the polyolefin family, which are inert and food compatible type.

[0031] In one exemplary instance (PP-EVOH-PP), the cup 2 is multilayered, the layers comprising an outer layer made of polypropylene, an intermediate barrier layer made of ethyl vinyl alcohol and an inner layer made of polypropylene.

[0032] In one exemplary instance (PE-EVOH-PE), the cup 2 is multilayered, the layers comprising an outer layer made of polyethylene, an intermediate barrier layer made of ethyl vinyl alcohol and an inner layer made of polyethylene.

[0033] In yet another exemplary instance, the cup 2 is biodegradable and compostable. In this exemplary instance (PLA-PVOH-PLA), the cup 2 is multilayered, the layers comprising an outer layer made of polylactic acid, an intermediate barrier layer made of polyvinyl alcohol and an inner layer made of polylactic acid.

[0034] As mentioned above, the cup 2 is made by means of a co-injection molding technique, which often presents problems related to the uniformity and homogeneity distribution of the intermediate barrier layer 72, while allowing to obtain complex and joined geometries. In order to ensure the uniform distribution of the intermediate barrier layer, the cup 2 is provided with a bottom 3 of specific external geometry, as shown in the different embodiment variants of Figure 2A , Figure 3 and Figure 4A .

[0035] The bottom 3 of the cup 2 comprises: an outer edge 86, corresponding to the inner edge 360, followed by an annular support portion 81, the outer edge and the annular support portion being intended to come into contact with the infusion chamber of the injection machine; a recess 85 for the connection to the nozzle 32. The support portion 81 is inclined towards the nozzle 32. The recess 85 is located below the labyrinth 30, when present.

[0036] The bottom 3 of the cup 2 does not present, between the support portion 81 and the nozzle 32, i.e. at the recess 85, radial reinforcing fins R present in the capsules of the prior art and visible for example in Figure 6A . In their place, the bottom 3 of the cup 2 is provided, between the support portion 81 and the nozzle 32, that is to say at the recess 85, with at least one reinforcing ring.

[0037] In Figure 2A, Figure 3 and Figure 4A In the exemplary example shown in

[0038] In the exemplary example shown in Figure 3 and Figure 4A In the exemplary example shown in Figure 4A the reinforcing ring is a continuous annular central ridge 83 extending inside the recess 85 from the bottom 3. The central ridge 83 can be cylindrical as in Figure 3 or wavy as in

[0039] In the exemplary example shown in Figure 4A the reinforcing ring is a continuous annular outer ridge 84 extending from the bottom 3 towards the support portion 81. The outer ridge 84 has an axial extension allowing it to come into contact with the infusion chamber of the injection machine to provide structural strength to the bottom 3 of the cup 2.

[0040] Instead of radial reinforcing fins R, the bottom 3 of the cup 2 is thickened at least at the recess 85. For example, the wall thickness at the recess 85 is between 0.8 mm and 1.2 mm compared to a wall thickness of approximately 0.5 mm in the rest of the cup 2.

[0041] Advantageously, the particular geometry of the bottom 3 of the cup 2, without radial reinforcing fins, allows a uniform distribution of the intermediate barrier layer 72 even in the presence of complex geometries integrated in the bottom 3, represented by the ridges 30, 90, 310 of the inner base.

[0042] Advantageously, the particular geometry of the bottom 3 provided with a thickened ring and / or a reinforcing ring ensures the necessary mechanical and structural strength of the cup 2 to withstand the high dispensing pressures to which the capsule is subjected during use without deforming.

[0043] Figure 6A and Figure 7A shows a cup 2’ of the prior art provided with radial reinforcing fins R at the bottom. The uneven distribution of the intermediate barrier layer 72’ is highlighted in the figure, with a strong alternation of thinner and thicker areas. At the upper welding edge 4’( Figure 7A ), the jagged pattern of the intermediate barrier layer 72’ is evident, with recesses in the wall and peaks appearing on the upper edge 4’.

[0044] Conversely, Figure 6B and Figure 7BA cup 2 according to the present application is shown, which does not have radial reinforcing fins at the bottom. The uniform distribution of the intermediate barrier layer 72 throughout the cup is highlighted in the figure. At the upper welding edge 4 ( Figure 7B ), a continuous pattern of the intermediate barrier layer 72 is evident, which ends just before the edge with a continuous profile. Advantageously, the cup 2 according to the present application does not have thinner areas, always guaranteeing the capacity of the intermediate layer to have a proper barrier to oxygen, without the need for greater amounts of this very expensive material. Furthermore, the cup 2 according to the present application does not have the surface of the barrier layer at the upper edge, thus ensuring the best sealing of the lid 6.

[0045] As mentioned above, the cup 2 is made by means of a co-injection molding technique, which allows to obtain complex and joined geometries, while not allowing the formation of openings in the wall directly during the molding step. Therefore, the cup 2 is initially molded as a single body, without interruptions or openings in the wall, but with a completely closed central portion 310, as shown in Figure 2B and Figure 4B The central portion 310 is a continuous wall, which completely closes the opening 31.

[0046] Preferably, the central portion 310 comprises an outer crown 311, which realizes the connection with the rest of the inner base 33, a flat portion 313, which provides a stop for the fixing of the sealing disc 5, and a central pin 312, which extends into the outlet opening 31 and the nozzle 32.

[0047] Subsequently, the cup 2 is sheared (or cut, or perforated) at the central portion 310 to form openings 314 in said central portion 310, in particular in the outer crown 311. After the shearing step, as shown in Figure 1 the central portion 310 has a plurality of connection openings 314 between the inside of the cup 2 and the outlet opening 31, to allow the flow of the infusion beverage towards the outside of the capsule 1. In an exemplary example, the shearing step provides a first step of cutting the central portion 310 and a subsequent step of bending the central portion 310 to form a plurality of fins 315.

[0048] Preferably, the inner wall of the nozzle is provided with a plurality of vertical fins 37 arranged uniformly in the circumferential direction, which are adapted to convey the infusion beverage flow towards the outlet opening 31.

[0049] Figure 1 A cup 2 is shown at the end of the production step, i.e. in which the central portion 310 is provided with a plurality of connection openings 314 between the inside of the cup 2 and the outlet opening 31. This cup 2 can be used to produce capsules 1 for the preparation of infusion beverages or soluble beverages.

[0050] ​The capsule 1 comprises a lid 6 fixed at the upper edge 4 by gluing or welding, which is adapted to seal the cup 2 at the top.

[0051] The capsule 1 is internally provided with a sealing disc 5, which is placed at the base 33 and is adapted to seal the cup 2 at the bottom. The capsule 1 is then provided with a closed chamber, which is defined at the top by the lid 6 and at the bottom by the disc 5, inside which the substance S to be infused or dissolved is contained. The presence of a hermetically closed chamber is important for the good preservation and protection of the substance. The disc 5 is located below the substance 11 and above the base 33.

[0052] The disc 5 is made of plastic material, in multiple or single layers, or plastic / aluminum composite or aluminum.

[0053] The disc 5 is internally fixed to the cup 2 at the base 33 at least on the upper surface of the edge 360, on the labyrinth 30 if present, and on the central portion 310.

[0054] In one exemplary instance, the disc 5 is tightly joined by using a heat-activatable material with low adhesion levels (in the case of a multiple-layer disc, a lacquer, a glue, a lower polymer layer) so as to allow the disc to separate or peel off from the base 33, and in particular from the edge 360, due to the increase in temperature and pressure inside the capsule 1.

[0055] In different exemplary instances, the disc 5 is permanently joined on the edge 360 and is opened by means of the opening device by perforation or tearing.

[0056] The capsule 1 can be made in different forms, for example for the preparation of an infusion beverage, such as coffee, or a soluble beverage.

[0057] Preferably, the coffee capsule 1 comprises a filter, which is fixed at the inner wall of the cup 2 below the substance S and just above the disc 5. The presence of the filter allows the infusion liquid to exit the capsule 1 after being filtered, the filter being preferably made of paper or non-woven (TNT).

[0058] Preferably, the coffee capsule 1 also comprises a permeable or microporous membrane, which is fixed at a suitable horizontal abutment provided inside the cup 2 at a distance above the substance S. The presence of such a membrane allows the passage of the pressurized fluid but not of the substance 11, preventing the dispersion of the coffee powder during the infusion step, thus improving the quality of the infusion beverage.

[0059] In the case where the capsule is used for the preparation of a soluble beverage, such as chocolate or milk, the capsule 1 comprises the lid 6 and the sealing disc 5, and is devoid of the filter and of the permeable or microporous membrane.

[0060] The capsule 1, in its various embodiments, can be used for the instant preparation of beverages (such as tea, coffee, herbal tea, milk, chocolate, etc.) by means of automatic or semi-automatic machines provided with a dispensing group adapted to perform the infusion by making pressurized hot water pass through the capsule 1.

[0061] Creatively, the cup according to the present application allows to obtain a capsule provided with a complex and engaging geometry, which is necessary for the optimal dispensing of the beverage, and at the same time a proper and uniform distribution of the intermediate barrier layer.

[0062] Advantageously, the bottom of the cup according to the present application (without radial stiffening fins) allows to obtain a uniform distribution of the intermediate barrier layer without thinner areas, thus ensuring a proper barrier against oxygen without the need for a greater amount of this expensive material, and without the need for surface finishing at the upper edge, thus ensuring the optimal sealing of the lid.

[0063] Advantageously, the bottom of the cup according to the present application is provided with a thickened ring and / or a reinforcing ring, ensuring the necessary mechanical and structural strength to withstand the high dispensing pressures to which the capsule is subjected during use.

[0064] It is clear that a person skilled in the art can make changes to the cup for capsules for the preparation of infused or soluble beverages described above, which all fall within the scope of protection defined by the following claims.

Claims

1. A co-extruded cup (2) made of plastic for producing capsules for preparing infused or soluble beverages, said co-extruded cup comprising: The entrance opening (21) is defined by the upper edge (4); The bottom (3) has an outer edge (86) and an outlet opening (31) defined by a nozzle (32) in the center, and the bottom has a middle annular support portion (81). The inner base (33) includes multiple vertically protruding ridges; The multi-layer wall (7) includes an outer layer (71), an inner layer (73) and an intermediate gas barrier layer (72), wherein the intermediate gas barrier layer (72) extends from the upper edge (4) to the nozzle (32). The bottom (3) has no radially reinforcing fins between the support portion (81) and the nozzle (32), and the intermediate gas barrier layer (72) extends uniformly from the upper edge (4) to the nozzle (32) without interruption.

2. The co-extruded cup (2) made of plastic according to claim 1, wherein, The bottom (3) has a wall thickness between 0.8 mm and 1.2 mm between the support portion (81) and the nozzle (32).

3. The co-extruded cup (2) made of plastic according to claim 1 or 2, wherein, The bottom (3) is provided with at least one reinforcing ring (82, 83, 84) between the support portion (81) and the nozzle (32).

4. The co-extruded cup (2) made of plastic according to claim 3, wherein, The reinforcing ring is a continuous annular inner ridge (82) that extends from the bottom (3) and is attached to the nozzle (32).

5. The co-extruded cup (2) made of plastic according to claim 3, wherein, The reinforcing ring is a continuous annular central ridge (83) that extends from the bottom (3) between the support portion (81) and the nozzle (32).

6. The co-extruded cup (2) made of plastic according to claim 3, wherein, The reinforcing ring is a continuous annular outer ridge (84) that extends from the bottom (3) toward the support portion (81).

7. The co-extruded cup (2) made of plastic according to claim 1, wherein, The intermediate gas barrier layer (72) is made of ethylene vinyl alcohol (EVOH) or polyvinyl alcohol (PVOH).

8. The co-extruded cup (2) made of plastic according to claim 1, wherein, Both the outer layer (71) and the inner layer (73) are made of polypropylene (PP), polyethylene (PE), or polylactic acid (PLA).

9. The co-extruded cup (2) made of plastic according to claim 1, wherein, The upper edge (4) and / or the nozzle (32) do not have an intermediate gas barrier layer (72).

10. The co-extruded cup (2) made of plastic according to claim 1, wherein, The intermediate gas barrier layer (72) extends into the inner base (33) and into the central pin (312) arranged within the nozzle (32).

11. A capsule (1) for preparing an infusion beverage or a soluble beverage, said capsule comprising: The cup (2) according to any one of the preceding claims has a plurality of openings (314) at the inner base (33) for connecting with the outlet opening (31). The food substance to be soaked or dissolved is contained in the cup (2); A lid (6) adapted to seal the cup (2) at the top, the lid being securely fixed to the upper edge (4); A sealing disc (5) is located below the food substance (11) and above the inner base (33), and the sealing disc is adapted to seal the cup (2) at the bottom.

12. The capsule (1) according to claim 11, wherein, The sealing disc (5) is sealed to the outer peripheral edge (360) of the inner base (33) in a yielding manner, and creates an opening for the beverage to overflow by separating the sealing disc (5) from the outer peripheral edge (360) at least partially.

13. The capsule (1) according to claim 11, wherein, The sealing disc (5) is permanently and sealed to the outer peripheral edge (360) of the inner base (33) and creates an opening for the beverage to spill out by breaking some weak parts of the sealing disc (5).

14. The capsule (1) according to claim 11, wherein, The sealing disc (5) is permanently and sealed to the outer peripheral edge (360) of the inner base (33), and an opening for the beverage to overflow is created by tearing the sealing disc (5) open by a perforating device.

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