Method for obtaining outlet opening of capsule

Abstract

The invention relates to a method for obtaining at least an outlet opening (8) of a carrier tray (7) which can be arranged in an interior space of a capsule (1) for preparing a beverage, the outlet opening (8) being adapted to allow the prepared beverage to flow out of the interior space towards the outside of the capsule (1) when the capsule (1) is used in the beverage preparation device. The method comprises the steps of:-providing a sheet material (70) from which the carrier tray (7) having the outlet openings (8) can be obtained,-cutting the sheet material (70) by means of a cutting device to obtain a first set of outlet openings (8),-cutting the sheet material (70) by means of an alignment element (101) extending through an alignment opening (71) provided in the sheet material (70) to obtain a second set of outlet openings (71), the first set of outlet openings is aligned with respect to the cutting device,-the sheet material (70) having the first set of outlet openings so aligned is cut by the cutting device to obtain a second set of outlet openings, and-the sheet material (70) is intermittently moved along different distances with respect to the cutting device.

Description

Technical Field

[0001] The present invention relates to a method for obtaining at least an outlet opening of a carrier tray of a capsule integrating a filter element for preparing a beverage, preferably crema-free coffee, tea, milk or a chocolate-based beverage. Background Art

[0002] Capsules for preparing beverages in beverage preparation devices and exhibiting the described characteristics are generally known in the prior art. The beverage preparation device comprises a brewing chamber in which the capsule is positioned. Liquid from the beverage preparation device is injected into the capsule to extract the beverage from an extractable component contained in the inner space of the capsule, typically roast and ground coffee or tea, or to prepare the beverage from a soluble component, typically instant coffee, instant tea or instant milk or chocolate-based products.

[0003] In most capsules currently on the market, the interior space of the capsule is air-tightly or liquid-tightly closed to protect from environmental influences before use in a beverage preparation device, so as to maintain or prolong the freshness of the beverage ingredients during storage.

[0004] Capsules to date generally comprise a substantially rigid capsule body having a circumferential side wall extending around an inner space and a base wall covering the inner space at a first end of the side wall. At a second end of the side wall opposite to the base wall, the capsule body has an open filling side. A liquid-tight and gas-tight cover, such as an aluminum cover, is arranged over the open filling side of the capsule body to cover the inner space. In use, the capsule can preferably be pierced at the base wall and / or the cover to form an injection opening for injecting a liquid, such as hot water, and / or to form an outlet opening allowing a prepared beverage to escape the capsule.

[0005] More specifically, the known capsule is conceived for preparing an espresso-type beverage using a beverage preparation device delivering highly pressurized hot water, wherein the injection of the pressurized hot water into the capsule results in the extraction of substances from the coffee beverage ingredients, and wherein the foam formed on the beverage corresponds to an espresso beverage with a crema layer obtained with known piston-type espresso machines using high-pressure brewing.

[0006] For coffee beverages without crema, e.g. coffee beverages without foam, also known as filtered coffee, special equipment is usually used, in which the beverage is prepared by non-pressure filtration of a mixture of beverage ingredients and water.

[0007] Some capsules for use in pressurized beverage devices have been proposed for preparing coffee without crema.

[0008] EP 2952125 A1 discloses a capsule for preparing a beverage using an extractable product contained in an inner space of the capsule. The capsule comprises a circumferential first wall; a second wall closing the circumferential first wall at a first end; and a flexible sheet-like perforated and / or porous third wall closing the circumferential first wall at a second open end opposite to the second wall, thereby forming the inner space. The third wall forms the outermost boundary of the capsule in its axial direction and comprises a woven or non-woven filter material, such as filter paper.

[0009] WO 2019 / 013623 A1 proposes a capsule comprising a rigid capsule body having a circumferential wall and a base wall, the circumferential wall and the base wall defining an interior space filled with a beverage ingredient. The open filling side of the capsule at the end of the circumferential wall opposite to the base wall is covered with a cover of a liquid-tight material. The cover is provided with a preformed outlet opening, which is suitable for allowing the prepared beverage to flow out of the interior space when the capsule is used in a beverage preparation device. The outlet opening is liquid-tightly closed by a removable covering element extending over at least a portion of the cover.

[0010] However, these solutions are not completely satisfactory with respect to the construction of the capsule, the ergonomic use of the capsule by the consumer and the in-cup result obtained. Furthermore, there is a need to manufacture the components of the capsule in a cost-effective and precise manner, in particular to obtain a high quality in-cup result.

[0011] Therefore, one object of the proposed invention is to provide a method for obtaining at least the components of a capsule suitable for preparing a filtered coffee beverage without crema having all the characteristics of a filtered coffee prepared with a drip coffee machine and complying with the desired organoleptic in-cup result expected by the consumer in a cost-effective and precise manner. Summary of the invention

[0012] In this respect, the present invention provides a method for obtaining at least an outlet opening of a carrier tray which can be arranged in an inner space of a capsule for preparing a beverage, wherein the outlet opening is adapted to allow the prepared beverage to flow out of the inner space towards the outside of the capsule when the capsule is used in a beverage preparation device, wherein the method comprises the following steps:

[0013] - providing a sheet material from which a carrier tray with an outlet opening can be obtained,

[0014] - cutting the sheet material by means of a cutting device to obtain a first set of outlet openings,

[0015] - aligning the first set of outlet openings relative to the cutting device by means of an alignment element extending through an alignment opening (guide hole, center hole, positioning hole, reference hole, etc.) provided in the sheet material, and

[0016] - Cutting the sheet material having the first set of outlet openings thus aligned by means of a cutting device to obtain a second set of outlet openings.

[0017] In particular, "alignment" may include guiding, centering and / or positioning relative to the cutting device. By means of an alignment element extending through the alignment opening, at least the first set of outlet openings may be automatically centered relative to the cutting device. Thus, the alignment opening may be used in the cutting device to "automatically center" the cutting of the hole.

[0018] Thus, a first set of outlet openings and a second set of outlet openings, which together form at least a part of the outlet openings of the carrier disc to be obtained from the sheet material, can be manufactured very accurately, i.e. with a high degree of precision. This is because the step of aligning the first set of outlet openings relative to the cutting device ensures that the second set of outlet openings is cut in a defined manner relative to the first set of outlet openings. Thereby, the second set can be arranged accurately relative to the first set, in particular so that the outlet openings of the set consisting of the outlet openings of the first set and the outlet openings of the second set are evenly, i.e. uniformly, distributed. In particular, at least a first set and a second set of outlet openings can be obtained so that these sets are adjacent to each other or overlap each other. Sets of outlet openings that overlap each other mean that at least some of the outlet openings of one of the sets are arranged between at least some of the outlet openings of the respective other set of the sets, so that each outlet opening comprised by the overlap thus formed does not merge with another outlet opening.

[0019] In particular, the outlet openings thus obtained, including at least a first set and a second set of outlet openings, can be arranged very close to each other, whereby a carrier disc having a particularly large number of outlet openings, which are precisely arranged relative to each other, can be obtained. In addition, the precisely arranged outlet openings thus obtained do not require complex manufacturing equipment, since the method in particular makes it unnecessary to obtain a very large number of outlet openings arranged very close to each other in a single cutting step. Instead, a very large number of outlet openings are obtained in at least two cutting steps, which outlet openings can also be arranged very close to each other in a precise manner, or in other words, a very large number of outlet openings is obtained divided into several cutting steps or distributed over several cutting steps, for example using a smaller number of cutting stations. In particular, the cutting pressure can thereby be reduced and the space required for the cutting device can be reduced. The latter is in particular because the cutting device does not need to provide a very large number of outlet openings at once. Instead, the cutting device can be adapted to provide only a part of the total number of outlet openings of the carrier disc, which can save space. In other words, at least a portion of the outlet openings of the carrier plate can be provided by the following steps: cutting a first set of outlet openings by a cutting device, advancing or moving the sheet material relative to the cutting device, aligning the first set of outlet openings, and then cutting a second set of outlet openings having the same hole pattern by the cutting device.

[0020] Furthermore, obtaining the outlet opening of the carrier disc in at least two cutting steps has the advantage that during the entire cutting process a particularly small number of small particles are obtained which would fall off as waste during cutting. Thus, material efficiency is increased.

[0021] The outlet openings thus obtained, arranged in a very precise manner (obtained, for example, with a tolerance of less than 0.1 mm) and preferably provided in a very large number, can advantageously be used in a carrier tray of a capsule for preparing a beverage. For example, when the capsule contains roast and ground coffee as beverage ingredient, the particular structure of the carrier tray, in particular defined by the outlet openings, allows obtaining, after removing the lid, a coffee with limited formation of foam and crema when the capsule is extracted in the preparation of a beverage. Such freshly brewed coffee can have the main characteristics of a filter-like coffee, with very little crema that disappears quickly (in less than 1 or 2 minutes) leaving only a ring of crema around the cup. The result in the cup is a coffee with low body, very low acidity and little bitterness and not strong, while being aromatic, soft, smooth and sweet. In particular, the outlet openings can be obtained in such a way that, when included by the carrier tray arranged in the inner space of the capsule, the formation of water channels within the coffee mass (in the capsule) during extraction can be avoided.

[0022] In the context of the present invention, "cutting" should be understood to cover different cutting techniques or cutting methods. For example, cutting may include or may be punching. Additionally or alternatively, cutting may include or may be cutting by using heat (e.g., by using a laser) and / or by using chip shaping (e.g., drilling) and / or by using other methods involving shearing.

[0023] The method may comprise the step of detecting the alignment opening, wherein, once detected, an alignment step is performed in which the alignment element is moved to extend through the alignment opening thus detected. The detection may be performed by optical means.

[0024] The method may further comprise the steps of: aligning the set of outlet openings relative to the cutting device by means of an alignment element extending through a further (e.g. second) alignment opening (guide hole, center hole, positioning hole, etc.) provided in the sheet material; and cutting the sheet material having the set of outlet openings thus aligned by means of the cutting device to obtain a further (e.g. third) set of outlet openings. Thus, the same alignment element may be used for aligning the first set of outlet openings and for aligning at least the first set and the second set of outlet openings relative to the cutting device in a further alignment step, so that in a subsequent cutting step a third set of outlet openings, e.g. adjacent to the second set of outlet openings, is obtained. Thus, it becomes simpler to obtain a large number of outlet openings with high precision. For example, the further (or third) set of outlet openings has a hole pattern that is identical to the hole pattern of each of the first set and the second set.

[0025] The method may further comprise the steps of: aligning a set of outlet openings (such as the first to third sets) relative to the cutting device by means of a further (such as a second) alignment element extending through the alignment openings provided in the sheet material; and cutting the sheet material having the set of outlet openings thus aligned by means of the cutting device to obtain an additional (or a further, such as a fourth) set of outlet openings. The further alignment element may align the set of outlet openings relative to a portion of the cutting device which is different from the portion of the cutting device relative to which the (first) alignment element aligned at least the first set of outlet openings. Thereby, it is particularly possible that the additional set of outlet openings has a hole pattern which is different from the hole pattern of each of the first set and / or the second set and / or the third set (if present) of outlet openings. Thus, the outlet openings may be obtained in a very advantageous manner, for example by comprising overlapping sets of outlet openings each having a different hole pattern.

[0026] The method may further comprise the steps of aligning a set of outlet openings, such as the first to fourth sets, relative to the cutting device by means of a further alignment element extending through further alignment openings provided in the sheet material; and cutting the sheet material having the set of outlet openings thus aligned by means of the cutting device to obtain a further (or even a further, e.g. fifth) set of outlet openings. For example, the same alignment element may be used for aligning the first to third sets of outlet openings and for aligning the first to fourth sets of outlet openings in a further alignment step, such that in a subsequent cutting step a fifth set of outlet openings is obtained, e.g. adjacent to the fourth set of outlet openings but overlapping one or more of the first to third sets of outlet openings. For example, the further (or fifth) set of outlet openings has a hole pattern that is the same as the hole pattern of the fourth set.

[0027] The method may further comprise the steps of aligning a set of outlet openings (such as the first to fifth sets) relative to the cutting device by means of a further alignment element extending through an additional (or further, e.g. a third) alignment opening provided in the sheet material; and cutting the sheet material having the set of outlet openings thus aligned by means of the cutting device to obtain an additional (such as a sixth) set of outlet openings. For example, the sixth set of outlet openings has a hole pattern that is the same as the hole pattern of each of the fourth and fifth sets.

[0028] At least a portion of the outlet openings of one set of outlet openings may be arranged between the outlet openings of the respective other set of outlet openings. In other words, the one set may overlap the respective other set. For example, the other set can be arranged such that at least a portion of the openings is surrounded by a portion of sheet material, wherein at least one outlet opening of the one set is cut in the portion of sheet material, whereby the outlet opening is arranged between the outlet openings of the other set. Thus, a particularly large number of outlet openings can be arranged close to each other in a precise manner.

[0029] The method may further comprise a step of cutting the sheet material by a cutting device to obtain the aligned openings. In particular, the aligned openings may be obtained in a cutting step for obtaining a first set of outlet openings. For example, the cutting step for cutting the sheet material for obtaining a first set of outlet openings may implement a hole pattern comprising aligned openings. The cutting device may have a first cutter for obtaining the first set of outlet openings and a second cutter for obtaining the aligned openings, wherein the cutters are kept at a fixed distance from each other during cutting. Further aligned openings may be obtained in a cutting step for obtaining a second set of outlet openings. Additional aligned openings may be obtained in a cutting step for obtaining a further set of outlet openings. Further aligned openings and / or additional aligned openings may be obtained by the same cutter for obtaining the aligned openings.

[0030] In other words, the first, second (or further), third (or additional) alignment openings may be formed with the first, second and third (or further) sets of outlet openings, respectively. Thus, the method may further comprise the step of cutting the sheet material by means of a cutting device to obtain the alignment openings, wherein, for example, the alignment openings are obtained in the cutting step to obtain the first set of outlet openings, the further alignment openings are obtained in the cutting step to obtain the second set of outlet openings, and the additional alignment openings are obtained in the cutting step to obtain the third (or further) set of outlet openings.

[0031] The diameter of the alignment opening and optionally the further alignment opening and, if present, the additional alignment opening may be greater than the diameter of each of the outlet openings. The alignment element may be a pin such as a guide pin. The diameter of the alignment opening may be greater than the diameter of each of the outlet openings, but equal to or (slightly) smaller than the diameter of the alignment opening. The alignment element may be adapted to extend through one or more alignment openings so as to align one or more sets of outlet openings relative to the cutting device. During the alignment step, the feeder supplying the sheet material may move the sheet material relative to the cutting device (i.e., the feeder releases the sheet material, e.g., the feeder does not tension the sheet material) so that by moving the alignment element through the alignment opening, the sheet material of at least the first set of outlet openings may be accurately positioned relative to the cutting device. The feeder may then prevent at least a portion of the sheet material of at least the first set of outlet openings from moving relative to the cutting device (e.g., by tensioning at least a portion of the sheet material), so that the sheet material can be cut in an easy manner.

[0032] The method further comprises the step of intermittently moving the sheet material relative to the cutting device along different distances (or advance strokes or steps). The different distances may comprise at least two or at least three (short) distances and at least one (long) distance greater than each of the (short distances). Thus, the sheet material may be moved during a first phase and stopped during a second phase, wherein at least the steps of aligning one or more sets of outlet openings and cutting another set of outlet openings are performed during the second phase. In other words, the sheet material may be moved relative to the cutting device at irregular advance strokes, such as three times at an advance stroke equal to distance A and a fourth time at an advance stroke equal to distance B, wherein B is different from (e.g. greater than) A. During the movement of the sheet material (i.e. when the sheet material is advanced), the alignment element may be located in a first position (such as a retracted position or an upper position) in which the alignment element is spaced a distance from the sheet material. When the sheet material stops, the alignment element may be in a second position (such as an extended position or a lower position into which the alignment element is moved downwards from the upper position) in which second position the alignment element extends through the alignment opening to align at least a first set of outlet openings. By intermittently moving the sheet material along different distances relative to the cutting device, complex patterns of outlet openings of a (single) carrier tray (such as a staggered set of outlet openings forming the outlet openings of the carrier tray) can be obtained in a very easy manner.

[0033] The method may also include the step of moving the sheet material relative to the cutting device from a first position where a first set of outlet openings is obtained along a distance (such as a stroke) to a second position where a second set of outlet openings is obtained. The cutting device may be stationary while the sheet material is moving. Alternatively, the sheet material may be stationary while the cutting device is moving. In these two positions, the same hole pattern (e.g., by using the same cutting station) or different hole patterns (e.g., by using different cutting stations, respectively) may be obtained.

[0034] The method may also include the step of moving the sheet material relative to the cutting device from the second position along a further (second) distance to a third position, in which a further (such as a third) or additional (such as a fourth) set of outlet openings is obtained, wherein the further distance is equal to or greater than the distance. For example, the further distance is equal to the distance when the same hole pattern is obtained in all three positions. The further distance may be greater than the distance when a different hole pattern is obtained in the third position than in the second position. For example, a larger distance can be used to move the sheet material to a different cutting station, such as a different punching machine.

[0035] The method may further comprise the step of cutting the sheet material by means of a cutting device to obtain the carrier disc such that the carrier disc comprises a set of outlet openings. The step of cutting the sheet material to obtain the carrier disc may be performed in a production line different from the production line in which the at least first and second sets of outlet openings are obtained. In other words, the cutting device may comprise a first component (such as one or more first cutting stations) for obtaining the at least first and second sets of outlet openings and a second component (such as one or more second cutting stations) for obtaining the carrier disc, wherein the second component may be located at a different position than the first component.

[0036] The method may further comprise the steps of aligning the set of outlet openings relative to the cutting device by using an alignment element extending through the alignment opening and / or (if present) through another alignment opening provided in the sheet material, such as through a further alignment opening or an additional alignment opening; and cutting the sheet material by the cutting device (or by a cutting station different from and / or spaced apart from the one or more cutting stations that obtain at least the first set and the second set) to obtain a carrier disc, such that the carrier disc comprises the set of outlet openings thus aligned. Thereby, the outlet openings can be arranged very precisely in the carrier disc, in particular at a defined distance from the periphery of the carrier disc, or at least positioned within a circumferential cutting line. In particular, it is avoided that the cutting device cuts through the outlet openings provided in the sheet material. In particular, a carrier disc can be obtained such that the carrier disc has no outlet openings on its periphery over a distance of at least 1 mm, preferably between 0.5 mm and 2.5 mm and more preferably between 1 mm and 2 mm. Thereby, safe and easy assembly in a capsule is possible.

[0037] Obtaining the outlet openings of the carrier tray can be a first production step, wherein obtaining the carrier tray including these outlet openings can be a second production step. The first production step and the second production step can be carried out on different production lines, respectively. For example, the production lines are independent of each other (especially, can be operated independently of each other) and / or are spaced a certain distance from each other. The first production step can be carried out at the location of the first supplier, wherein the second production step can be carried out at the location of the second supplier. Between the production steps, the sheet material (for example as a sheet roll) including the outlet opening can be transported. Obtaining the carrier tray or the second production step can be part of a filling device or machine or a filling line. In the filling device or machine or filling line, the capsule body can be filled with a beverage ingredient, wherein after the filling step, the sheet material can be cut to obtain the carrier tray (for example, together with a filter element). After obtaining the carrier tray, the carrier tray (and for example together with a filter element) can be transferred to or in the capsule.

[0038] In particular, the carrier disc may be obtained (eg stamped) in alignment with a hole pattern defined by at least two sets of outlet openings.

[0039] The cutting device may be a punching device, wherein, preferably, cutting at least the first set and the second set of outlet openings is performed by the same punch or by different punches, respectively. The punching device may comprise one or more dies arranged relative to the same punch or to different punches. By means of the punching device, the set of outlet openings may be obtained by a reciprocating motion, such as by moving the punch downwards and moving the punch upwards.

[0040] The method may further comprise the step of providing a carrier tray in the inner space of the capsule for preparing the beverage.

[0041] The method may further comprise the step of providing a filter element.The filter element may comprise a layer of nonwoven material adapted to prevent the passage of the escaping coffee and to reduce the formation of a crema layer.

[0042] The method can be carried out in a multi-line production line or in a multi-line machine.

[0043] The method may comprise a filling step, such as filling the beverage ingredient into the capsule body. After filling the beverage ingredient, at least two sets of carrier trays comprising outlet openings can be arranged in the capsule body. In other words, the method may be used in a multi-line filling machine or production line. The filling may be performed by one or more filling stations, such as at least two filling stations, preferably six or more filling stations, more preferably eight or more filling stations, even more preferably twelve or more filling stations, for example twenty-four or more filling stations.

[0044] The method may further comprise the step of positioning the filter element on the carrier plate. This makes the capsule assembly process easy to handle. In addition, the method may comprise the step of fixing the filter element (eg positioned on the carrier plate) to the carrier plate.

[0045] The outlet openings of one set of outlet openings may be spaced apart from adjacent outlet openings of another set of outlet openings by a distance of between 0.5 mm and 3 mm, and more preferably between 1 mm and 3 mm. In particular, the outlet openings of one set of outlet openings arranged between the outlet openings of another set of outlet openings may be spaced apart from these outlet openings by a distance of between 0.5 mm and 3 mm, and more preferably between 1 mm and 3 mm.

[0046] Adjacent outlet openings of the same set of outlet openings may be spaced apart from each other by a distance that is greater than a distance between adjacent outlet openings of a different set of outlet openings.

[0047] The set of outlet openings or the outlet openings of the carrier tray, in particular the set of outlet openings comprised by the carrier tray, may comprise between 50 and 150 outlet openings, preferably between 70 and 120 outlet openings, more preferably between 85 and 110 outlet openings. Such a structure with a plurality of openings is particularly advantageous for avoiding water channels within the coffee mass during extraction.

[0048] The set of outlet openings or the outlet openings of the carrier plate, in particular the set of outlet openings comprised by the carrier plate, may comprise between 1 / 4 and 2 / 8 of the outlet openings per mm. 2 Between 0.07 and 0.21 outlet openings, preferably between 0.07 and 0.21 outlet openings per mm 2 Between 0.10 and 0.17 outlet openings, more preferably between 0.10 and 0.17 outlet openings per mm 2 Exit opening between 0.12 and 0.16.

[0049] The opening area ratio of the carrier plate may be between 4% and 15%, preferably between 5% and 12%. The opening area ratio is set so that no pressure accumulation occurs in the capsule or pressure accumulation is reduced during the extraction process.

[0050] The outlet opening may be a calibrated circular or oval opening. Such shapes of the outlet opening shape are optimized for ease of manufacture and reduced processing costs. However, other shapes of outlet openings may be selected depending on the in-cup results to be obtained.

[0051] The diameter of the outlet opening may be between 0.4 mm and 3 mm, preferably between 0.5 mm and 2 mm, more preferably between 0.5 mm and 1.3 mm. These dimensions have been calculated for a leakage rate of approximately 300 ml / min.

[0052] The outlet openings can be evenly distributed over the surface of the carrier disc. This helps to avoid channeling effects.

[0053] Each outlet opening of the carrier disc may be spaced apart from an adjacent outlet opening by a distance of between 0.5 mm and 3 mm and more preferably between 1 mm and 3 mm.

[0054] The carrier platter may have a generally circular shape with a diameter between 28.5 mm and 30.5 mm. Alternatively, the carrier platter may have another shape, such as an oval, polygonal or rectangular shape.

[0055] The thickness of the sheet material of the carrier disc may be between 0.05 mm and 1.5 mm, preferably between 0.1 mm and 1 mm, most preferably between 0.2 mm and 0.8 mm. Thus, the carrier disc has sufficient rigidity to resist ejection during extraction or after extraction due to the pressure of the expanding coffee mass. In one embodiment, the thickness of the sheet material is about 0.3 mm (300 μm).

[0056] The sheet material may be made of aluminium. This allows easy recycling in conventional aluminium streams, in particular when the remaining capsules are also made of aluminium. Additionally or alternatively, the carrier tray may be made of plastic or a laminated plastic element.

[0057] The sheet material may be provided as or from a sheet roll. The sheet roll may have a width (e.g., the portion of the sheet material extending transversely to the direction of movement of the sheet material) that is greater than at least twice the diameter of a carrier disc to be obtained from the sheet material. The sheet material may be in the form of a foil.

[0058] According to another aspect, the present invention provides a capsule for preparing a beverage. The capsule comprises:

[0059] - a substantially rigid capsule body having a circumferential side wall extending around an interior space of the capsule, said interior space being at least partially filled with a beverage ingredient suitable for preparing the beverage;

[0060] - a rigid base wall integral with the capsule body, which covers the inner space at a first end of the side wall;

[0061] - a flange arranged circumferentially around the opening side of the capsule at a second end of the side wall of the base body opposite the base wall;

[0062] - a cover covering the interior space and the open side of the capsule at a second end of the side wall opposite the base wall and tightly closing the capsule, the cover being removably attached to the flange for using the capsule in a beverage preparation device;

[0063] - a filter element positioned in the interior space of the capsule between the beverage ingredients and the lid, and

[0064] - a carrier tray comprising an outlet opening obtained by a method as described above, wherein the carrier tray is arranged in the inner space of the capsule,

[0065] - wherein the carrier tray is positioned in the interior space of the capsule between the cover and the filter; and

[0066] - wherein the carrier tray comprises between 50 and 150 outlet openings and the opening area ratio of the carrier tray is higher than 4%.

[0067] Considering that the capsule is to be extracted in a beverage preparation device comprising an extraction plate with a tearing surface, the outlet openings may be evenly distributed on the carrier tray, with less than 10% of the outlet openings of the carrier tray directly facing the tearing surface of the extraction plate. This feature is such that the extracted coffee is not prevented from leaving the carrier tray and is not affected by the tearing surface near the extraction plate.

[0068] Furthermore, the pattern in which the outlet openings are distributed on the carrier disc may be configured such that the outlet opening distribution is independent of the angular positioning of the carrier disc relative to the tearing surface of the extractor plate.

[0069] The lid of the capsule may comprise a free pull tab protruding from the lid. The pull tab may be integral with the lid so that the entire lid can be removed. Such handling and opening is thus easier.

[0070] In one embodiment, the cover comprises at least one aluminium layer to ensure a better shelf life of the coffee in the capsule.

[0071] Furthermore, the cover may also include a plastic layer and / or a heat seal layer to ensure food grade compatibility, thereby sealing the cover to the flange of the capsule.

[0072] Preferably, the capsule body, the lid and the carrier tray are all made mainly of aluminum. The use of aluminum ensures better coffee protection and longer shelf life. In addition, the end of life of the capsule is easier and recycling is easier.

[0073] In an alternative, the capsule body, the cover and the carrier tray may each be made of plastic or of laminated or multi-layered plastic elements.

[0074] The beverage ingredient is preferably ground coffee, preferably in an amount of at least 4g, preferably between 4.5g and 15g.

[0075] Due to the proposed capsule construction, the carrier tray can be positioned inside the capsule and at a distance of, for example, between 0.1 mm and 2 mm from the lid. This avoids possible interaction between the carrier tray and the tearing surface of the extraction plate of the beverage preparation device when the coffee mass volume expands during extraction.

[0076] The capsule may be designed to maintain extraction of the beverage ingredient during an extraction process performed at a pressure below 8 bar, more preferably below 5 bar.

[0077] The present invention also provides a system as described herein.

[0078] The system of the invention is intended for preparing a beverage. The system comprises a replaceable capsule, such as the capsule described above, and a beverage preparation device having a fluid dispensing device capable of supplying a quantity of fluid, such as water, to the capsule at a pressure between 0.1 bar and 20 bar, and a brewing chamber comprising a first part for holding the capsule and a second part for closing the brewing chamber.

[0079] The system proposes the use of a replaceable capsule incorporating one or more of the features disclosed above in a beverage preparation device, wherein a second part of a brewing chamber of the beverage preparation device comprises an extraction plate for engaging the replaceable capsule at a second end of the side wall while keeping the brewing chamber of the capsule closed, the extraction plate comprising a tearing surface which, in use, faces a carrying tray at this second end of the capsule, wherein the carrying tray of the capsule is not altered by the tearing surface of the extraction plate when in use in the closed brewing chamber, and wherein, in use, less than 10% of the outlet opening directly faces the tearing surface of the extraction plate.

[0080] More specifically, the tear-off surface of the extractor plate may comprise pyramidal elements and, depending on the outlet opening distribution, less than 10% of the outlet openings directly face the pyramidal elements of the tear-off surface.

[0081] Advantageously, the pattern in which the outlet openings are distributed on the carrier disc is also configured such that the outlet opening distribution is independent of the angular positioning of the carrier disc relative to the tearing surface of the extractor plate.

[0082] The extraction of the beverage ingredient may be an extraction carried out at a pressure below 8 bar, more preferably below 5 bar.

[0083] The invention also relates to the use of a capsule having one or more of the features disclosed above, alone or in a system having one or more of the features disclosed above.

[0084] The disclosure of European patent application No. 20210284.4 filed on November 27, 2020 is incorporated herein by reference.

[0085] Specific embodiments of the invention are described in the detailed description below. These objects are achieved by the present invention, namely the capsule, system and method for making the capsule. BRIEF DESCRIPTION OF THE DRAWINGS

[0086] The present invention is further described with reference to the following examples and drawings, which form a part of the present invention. Unless clearly and explicitly indicated, the drawings are not intended to reflect limitations on the scope of the present invention in any way. It should be understood that the present invention protected by the claims is not intended to be limited in any way to these exemplary embodiments and illustrations.

[0087] It is noted that the drawings are only schematic representations of embodiments of the invention given by way of non-limiting examples.

[0088] Embodiments of the present invention will now be described by way of example with reference to the following drawings, in which:

[0089] - FIG. 1 a is a perspective side view of a tightly closed capsule according to the invention before use in a beverage preparation device;

[0090] - FIG. 1 b is a perspective side view of a capsule according to the invention with the cover partially removed;

[0091] - Fig. 1c is a perspective side view of a capsule according to the invention, wherein the cover has been removed and is ready for use in a beverage preparation device;

[0092] - Figure 2a is a schematic cross-sectional view of a capsule according to a first embodiment of the present invention;

[0093] - Figure 2b is an enlarged view of the identified bottom portion of the capsule of Figure 2a;

[0094] - FIG. 2 c is a view of the carrier tray of the capsule of FIG. 2 a before being assembled into the capsule;

[0095] - FIG. 3 a is a schematic diagram of the carrier tray of the capsule of FIG. 2 a once assembled in a capsule having 4 crimping points according to the first proposed embodiment;

[0096] - FIG. 3 b is a schematic diagram of the carrier tray of the capsule of FIG. 2 a once assembled in a capsule having 8 crimping points according to the first proposed embodiment;

[0097] - Figures 4a, 4b and 4c are schematic diagrams of carrier plates with different hole distribution patterns according to the present invention;

[0098] - Figure 5 is a table showing different disc versions according to the invention, illustrating the dispersion evolution of crema over time in an extracted coffee beverage;

[0099] - Fig. 6a is a view of the proposed pore distribution pattern.

[0100] - Fig. 6b is a transparent overlay of the proposed hole distribution pattern of Fig. 6a and the tear surface of the extractor plate of the beverage preparation device at three different angular positions.

[0101] - Figure 7 is a schematic top view of a first set of outlet openings of a carrier tray obtained by a method according to an embodiment.

[0102] - Figure 8is the first outlet opening of the carrier plate obtained by the method according to one embodiment

[0103] Schematic top view of a first set and a second set.

[0104] - Fig. 9 is the first outlet opening of the carrier plate obtained by the method according to one embodiment

[0105] Schematic top view of the first set, the second set and the third set.

[0106] - Fig.10 is the outlet opening of the carrier tray obtained by the method according to one embodiment

[0107] Schematic top views of the first to fourth sets.

[0108] - Fig.11 is the outlet opening of the carrier tray obtained by the method according to one embodiment

[0109] Schematic top views of the first to fifth sets.

[0110] - Fig.12 is the outlet opening of the carrier tray obtained by the method according to one embodiment

[0111] Schematic top views of the first to sixth sets.

[0112] - Fig.13 A cutting device for cutting a sheet material by a method according to an embodiment

[0113] Schematic top view of the two sets of outlet openings obtained.

[0114] - Fig.14 is moved or displaced in the direction of movement of the sheet material relative to the cutting device Fig.13 and two further sets of outlet openings adjacent to the thus moved set of outlet openings and obtained by cutting the sheet material by a cutting device according to a method according to an embodiment.

[0115] - Fig.15 is moved or displaced in the direction of movement of the sheet material relative to the cutting device Fig.14 and two further sets of outlet openings adjacent to the thus moved set of outlet openings and obtained by cutting the sheet material by a cutting device according to a method according to an embodiment.

[0116] - Fig.16 is moved or displaced in the direction of sheet movement relative to the cutting device Fig.15Out

[0117] A schematic top view of a set of outlet openings and two further sets of outlet openings obtained by cutting a sheet material by a cutting device according to a method according to an embodiment, wherein one of these sets of outlet openings (in Fig.16 Middle: A set in the middle of the figure) is obtained by moving a part of the set so as to form the outlet opening of the carrier plate.

[0118] - Fig.17 is moved or displaced in the direction of sheet movement relative to the cutting device Fig.16 Out

[0119] A schematic top view of a set of outlet openings and two further sets of outlet openings obtained by cutting a sheet material by a cutting device according to a method according to an embodiment, wherein one of these sets of outlet openings is adjacent to a sheet material according to Fig.16 One of a set of obtained outlet openings is obtained so as to form an outlet opening of the carrier tray.

[0120] - Fig.18 is moved or displaced in the direction of sheet movement relative to the cutting device Fig.17 and a schematic top view of two further sets of outlet openings obtained by cutting a sheet material by a cutting device according to a method according to an embodiment, wherein one of these sets of outlet openings is adjacent to a sheet material according to Fig.17 One of a set of obtained outlet openings is obtained so as to form an outlet opening of the carrier tray.

[0121] - Fig.19 is a schematic top view of an extract of a sheet material from which a plurality of carrier trays can be obtained.

[0122] - Fig. 20 is a schematic side view of an exemplary production line used in a method according to one embodiment.

[0123] - Fig.21 is a schematic cross-sectional side view of a portion of a cutting device used in a method according to one embodiment.

[0124] - Fig. 22 Different schematic cross-sectional side views are shown, which respectively illustrate different stages of punching a sheet material to obtain an outlet opening in a method according to an embodiment. DETAILED DESCRIPTION

[0125] As used in this specification, the words "include", "comprising" and similar words should not be understood as having an exclusive or exhaustive meaning. In other words, these words are intended to mean "including but not limited to".

[0126] Any reference to prior art documents in this specification is not to be taken as an admission that such prior art is well known or forms part of the common general knowledge in the art.

[0127] Fig. 1a shows a capsule 1 before use in a beverage preparation device (defined as a storage state). Referring to Fig. 2, the capsule 1 of Fig. 1a comprises a rigid capsule body 2. The body 2 comprises a frustoconical side wall 2a extending circumferentially around the interior space of the body. The capsule further comprises a rigid base wall 3 integral with the capsule body 2, which closes the interior space at a first end of the side wall of the capsule body 2. A flange 4 extends radially outwards from a second end of the side wall of the capsule body 2a. At the second end of the side wall, the capsule body 2 has an open filling side.

[0128] Typically, the capsule body 2 is processed to food grade and comprises a lacquer layer or a polymer film layer (not shown) applied on the inner side of the capsule body.

[0129] The capsule further comprises a lid 5 attached to a flange 4 of the capsule body so as to sealingly close the capsule. The lid 5 can be manually removed from the capsule by pulling a free pull tab 6. In this case, the pull tab 6 is integral with the lid 5 and protrudes from the lid, but alternative solutions may also be used.

[0130] The cover 5 is a flexible sheet foil made of aluminium with a heat sealing lacquer or polymer layer on the sealing side.

[0131] In case the cover 5 comprises a lacquer layer on its sealing side, the thickness of the lacquer layer may be 0.003 mm to 0.03 mm. In case the cover 5 comprises a polymer layer on its sealing side, the thickness of the polymer layer may be 0.01 mm to 0.05 mm.

[0132] The cover 5, which is intended to be removed using a pull tab, is attached to the flange 4 using an adhesive layer. The adhesive material is applied in the form of an adhesive material layer and may be, for example, a heat-sealing lacquer layer or a polymer film layer.

[0133] For example, the sealing layer forming the adhesive material may be a layer between 0.003 mm and 0.03 mm.

[0134] The layer of adhesive material allows the cover 5 to be removed to the flange 4 of the capsule without causing any damage to the capsule 1 .

[0135] Before closing the capsule, the inner space of the capsule is filled with a beverage ingredient. In this case, the capsule is filled with coffee powder of roast and ground coffee before the capsule is tightly closed with the cover 5 to preserve the freshness of the roast and ground coffee. Depending on the size of the capsule, the weight of the coffee is in the range of 4 g to 15 g. However, tea, milk or chocolate ingredients can be envisaged.

[0136] The capsule of FIG. 1b shows the capsule of FIG. 1a , wherein the cover 5 is partially removed by tearing the pull tab 6 , and the same capsule is shown in FIG. 1c , wherein the cover 5 is completely removed. As shown, the second end (filling side) of the capsule is no longer closed, and a membrane defined as a carrier disc 7 is presented on the inner side of the capsule. The carrier disc 7 includes a plurality of preformed outlet openings (or holes) 8 for a beverage (here coffee) prepared in a beverage preparation device. The capsule also includes mechanical deformations 11a, 11b, 11c, ..., performed at the junction between the side wall 2a and the flange 4, which keep the carrier disc 7 in the inner space of the capsule. Four mechanical deformations 11 can be seen in FIG. 1b . These mechanical deformations 11a, 11b, 11c, ... are also visible on the capsule of FIG. 1c , and in fact eight mechanical deformations can be observed. These local deformations are made using a crimping process. Their function and completion will be explained in conjunction with FIG. 2a and below.

[0137] The preformed outlet opening 8 of the carrier tray 7 is covered by the lid 5 of the capsule, thereby closing the capsule to maintain an airtight seal of the interior space of the capsule, thereby ensuring the freshness of the beverage ingredients inside the capsule during storage.

[0138] As will be seen in the cross-sectional views of various embodiments of the capsule of the present invention (see for example Fig. 2a), the capsule further comprises in its inner space a filter element 9 positioned between the coffee mass and the carrier disc 7. The filter element 9 prevents solid particles of beverage ingredients (e.g. coffee particles or tea leaves) from flowing out of the capsule during extraction into the interior of the final consumer's cup.

[0139] The capsule body 2 and the cover 5 may each be made primarily of aluminum. However, other materials may be envisioned for the capsule body and the cover.

[0140] For example, the capsule body and the lid may be made of a plastic polymer material, or the capsule body and the lid may be made of a paper-based material.

[0141] As will be appreciated, the capsules are used in the same manner as conventional The invention relates to a beverage preparation device for extracting coffee capsules by using a conventional high pressure beverage preparation device compatible with the coffee capsule. The beverage preparation device comprises a fluid dispensing device capable of feeding a quantity of fluid, such as water, to the capsule at a pressure between 0.1 bar and 20 bar, and a brewing chamber comprising a first part for holding the capsule and a second part for closing the brewing chamber, the second part of the brewing chamber comprising an extraction plate presenting a tear-off surface for engaging with the capsule at its second end opposite to its base wall.

[0142] Summarizing the conventional extraction process of a closed capsule in a beverage preparation device: The capsule is inserted into the brewing chamber of the beverage preparation device. The fluid dispensing device feeds a certain amount of fluid (such as water) to the capsule through the base wall 3 inside the capsule to saturate the coffee and then extract it. When the pressure inside the capsule increases, the cover of the capsule comes into contact with the tear surface of the extraction plate and the cover is changed by the tear surface, thereby forming an opening that allows the coffee to flow out of the capsule.

[0143] An outlet opening for the coffee to flow out is formed at the surface of the lid by the interaction of the lid with the tear-off surface, which participates in the formation of foam and cream during the preparation process.

[0144] The use of conventional capsules (closed capsules) in the above process results in coffee extraction at pressures between 8 and 20 bars.

[0145] During extraction of the capsule, the cover of the capsule is removed before inserting the capsule inside the brewing chamber of the beverage preparation device. The fluid dispensing device feeds a certain amount of fluid, such as water, to 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 tray 7. During extraction, the carrier tray 7 (which is at a certain distance from the flange of the capsule) is not intended to come into contact with the tearing surface of the extraction plate of the beverage preparation device. The carrier tray 7 is not changed by tearing during extraction of the capsule (as in the case of conventional extraction of a closed capsule, where the capsule membrane is torn on the tearing surface of the extraction plate, as explained in the previous section).

[0146] The use of the capsule (in conventional beverage preparation devices) results in coffee extraction at pressures between 0.1 bar and 8 bar, depending on the amount of coffee inside the capsule and the filter element structure.

[0147] Since the cover is removed from the capsule before using the capsule in the beverage preparation device and when the carrying tray is located inside the capsule (see for example Fig. 2a), the carrying tray is not intended to come into contact with the tearing surface of the extraction plate and is therefore not deformed by said tearing surface.

[0148] In more detail, when using the capsule 1 in a beverage preparation device to prepare coffee, the user removes the cover 5 by tearing 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 means of the beverage preparation device for supplying water under pressure into the capsule to prepare a coffee beverage.

[0149] Since the capsule is not closed when used in a beverage preparation device (lid 5 removed and outlet opening accessible), the extraction pressure built up inside the capsule is limited (0.1 to 6 bar) and the formation of foam and cream during extraction is limited.

[0150] Hence, the resulting coffee in the cup has little or no crema, since instead of a pressure build-up and sudden pressure drop occurring upon interaction between the coffee / lid / opening element and the tear-away surface of the extraction plate of the beverage preparation device (as with conventional capsules), the resulting coffee has little or no crema.

[0151] The capsules can be used to prepare coffee, tea, milk or chocolate without crema, depending on the beverage ingredients inside the capsule.

[0152] Fig. 2a shows a first embodiment of the capsule.As disclosed, the capsule comprises within the inner space a carrier disc 7 comprising a plurality of pre-formed outlet openings 8 (ie a perforated carrier disc).

[0153] As shown in FIG. 2 b (an enlarged cross-sectional view of the bottom component portion identified in FIG. 2 a ), the carrier disc 7 is positioned inside the capsule at a distance between 0.1 mm and 2 mm from the lid 5 , which is sealed on the flange 4 .

[0154] This gap between the capsule cover 5 (and hence the flange 4 once the cover is removed for extraction) and the carrier tray 7 provides a recess so that if the carrier tray 7 flexes during the extraction process it does not form a tearing interface with the tearing surface of the extraction plate of the beverage preparation device.

[0155] The carrier disc 7 may be a substantially circular piece of material as shown in FIG. 2 c and having a diameter approximately equal to the inner diameter of the capsule at the location where the carrier disc 7 is positioned / inserted / retained (depending on the assembly process).

[0156] Thus, in the proposed embodiment, the diameter of the carrier disc 7 may be approximately 29.5 mm and 30.5 mm.

[0157] In the proposed embodiment, the carrier platter may be made of aluminum. Its thickness may be about 0.3 mm, but may vary between 0.1 mm and 1 mm.

[0158] The carrier tray may be made of aluminium, and in a preferred solution, as shown in the drawings, the capsule body, the lid and the carrier tray are all mainly made of aluminium.

[0159] In the proposed solution, the carrier disc 7 is held inside the capsule thanks to a local mechanical deformation 11 formed on the capsule at the junction between the side wall 2a of the capsule 1 and the flange 4. In the detailed cross section of Figure 2b, one mechanical deformation 11 is visible. The mechanical deformation is in the form of a curling point 11 and is located on the side of the capsule on the opening side opposite to the base wall 3.

[0160] Since the capsule is made of a ductile material, preferably aluminium, the mechanical deformation made by crimping allows to locally reduce the diameter and thereby retain the carrier disc 7 (and the filter) inside the capsule.The carrier disc is then retained inside the capsule 1 .

[0161] Here, during the manufacturing process, before closing the capsule with the lid 5 , a step is performed on the capsule of mechanically deforming the capsule at the junction of the flange 4 with the side wall 2 a , which leads to the crimping point 11 .

[0162] At the junction of the flange and the side wall of the capsule, there are between 2 and 10 curling points 11 (also visible in FIG. 1 c ) distributed angularly around the periphery of the opening side of the capsule.

[0163] The curling points 11 will preferably be evenly distributed over the circumference of the open side of the capsule, taking into account the tool used to make them.

[0164] Furthermore, depending on the crimping tool used, the crimping point 11 can have a circular crimping impression.

[0165] In an alternative, the carrier tray 7 may be made of a plastic or laminate film comprising, for example, a polyolefin such as polypropylene, polyethylene or any other semi-crystalline polymer. The carrier tray 7 may also be made of a paper-based material such as coated paper, laminated paper or moulded paper.

[0166] As shown in Fig. 2c, the preformed outlet openings 8 may be circular openings evenly distributed on the surface of the carrier disc. Such even distribution of the outlet openings ensures an even flow of coffee out of the capsule 1. This also helps to avoid the beverage (coffee powder) from forming channels inside the capsule.

[0167] The diameter of the opening may be set at about 0.75 mm to 1 mm, but the diameter may vary between 0.4 mm and 3 mm, most preferably between 0.5 mm and 1.3 mm.

[0168] The number of preformed outlet openings can vary depending on the size of the capsule (and on the size of the carrier tray) and the desired coffee delivery speed. In the disclosed embodiment, the carrier tray 7 comprises between 50 and 150 openings, preferably about 90 openings, and in the presented embodiment about 100 outlet openings.

[0169] In an alternative embodiment, the pre-formed outlet opening may be oval in shape.

[0170] As shown, the capsule may also include a filter element 9 which is positioned on the ingredient mass (e.g. coffee mass) after the capsule is filled during a possible assembly process, and the carrier disc 7 is positioned between the filter element and the cover 5. In an alternative assembly process, the filter is assembled to the carrier disc and both elements are inserted into the capsule on the ingredient mass.

[0171] As shown in the enlarged view of Figure 2b, when the capsule is inverted, the filter element 9 is located on the carrier disc 7. The filter element is then supported by the carrier disc 7 inside the container. The filter remains flat inside the capsule and does not come into contact with the tear surface of the extraction plate of the beverage preparation device during extraction.

[0172] The use of a two-piece design may enable the use of non-sealable filter materials, which is advantageous in terms of sustainability.

[0173] As proposed in this embodiment, the filter element 9 is circular and has a diameter smaller than the diameter of the carrier disc 7, ie between 28 mm and 30.5 mm, and typically 0.1 mm smaller than the carrier disc.

[0174] However, in alternative embodiments, the diameter of the filter element 9 may be similar to the diameter of the carrier disc 7 .

[0175] The filter element 9 may be made of a nonwoven material suitable for preventing / inhibiting the escaping coffee from passing too slowly or too quickly during extraction of the beverage, in order to avoid the creation of a crema layer and to avoid the escaping coffee from passing directly through the carrier tray to the cup.

[0176] The filter element 9 of the proposed embodiment may have a thickness between 20 microns and 300 microns, 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 may be a paper-based filter element.

[0177] The filter element may include a layer of nonwoven material joined to another filter layer by any known means.

[0178] In the proposed embodiment of Figures 2a to 2c, the filter element 9 and the carrier disc 7 are separate elements positioned relative to each other. However, they can be assembled together, for example by gluing or in any other way. This will then change the assembly process in the capsule, since the insertion of the filter and the carrier disc will be carried out in one step. The filter element 9 and the carrier disc 7 can form one component together.

[0179] The proposed circular carrier disc 7 may have a conical shape on its periphery in order to fit (press fit) into a capsule having a frustoconical shape. However, other alternative shapes and arrangements of the carrier disc within the capsule may be envisaged.

[0180] Preferably, the carrier disc 7 and the filter element 9 remain in place inside the capsule when the cover 5 is removed and the capsule 1 is extracted in a beverage preparation machine. Several assembly processes are contemplated and will be disclosed later in conjunction with the proposed embodiment of the capsule.

[0181] In a variant embodiment not shown, the carrier disc can be made of plastic or laminated plastic elements. In this case, the assembly process of the carrier disc in the capsule will remain similar.

[0182] Figures 3a and 3b show the capsule of Figure 2a (viewed from the open side of the capsule) with the carrier disc 7 inserted into the capsule of Figure 2a once assembled in the capsule, with 4 and 8 curling points respectively before closing the open side of the capsule by attaching the lid. It can be seen that the hole distribution pattern of the carrier disc 7 is the same, but is viewed at two different angular positions.

[0183] The number of crimping points (mechanical deformations) may vary between 2 and 10, allowing the carrier disc 7 (and the filter element 9 supported by it) to be adequately and effectively retained inside the capsule 1 .

[0184] The curling points 11 are angularly distributed around the periphery of the open side of the capsule at the junction between the side wall 2a of the capsule and the flange 4. Preferably, as presented here, the curling points are evenly distributed along the periphery of the open side of the capsule.

[0185] The tools currently used have a rounded end shape during the step of mechanically deforming the capsule, allowing to have a curling point with a substantially circular curling impression.

[0186] Figures 4a, 4b and 4c show different satisfactory versions of a carrier disc 7 with different hole distributions to be inserted into the inner space of the capsule body 2. As already seen in the previous figures, the carrier disc 7 comprises a plurality of preformed outlet openings 8 suitable for letting the prepared beverage flow out of the inner space of the capsule towards the outside of the capsule when the capsule is used in the beverage preparation device.

[0187] The carrier disc 7 may be a preferably circular aluminium disc, the diameter of which may be set to 30 mm + / - 3 mm. However, depending on the size and / or configuration of the capsule, the diameter of the carrier disc may be between 28.5 mm and 30.5 mm.

[0188] The thickness of the carrier disc 7 used in the capsule of Figure 2a may be about 0.3 mm. However, the thickness of the carrier disc may vary. It may range between 0.05 mm and 1.5 mm, preferably between 0.1 mm and 1 mm, and most preferably between 0.2 mm and 0.8 mm.

[0189] The carrier disc may have a void space 10 which is free of outlet openings over a distance of at least 0.5 mm on its periphery in order to avoid that some outlet openings are damaged and / or overlapped by crimping points during assembly (visible in FIGS. 3a and 3b ). The void space 10 is particularly visible in FIG. 4a .

[0190] As shown, the outlet openings 8 are preformed calibrated circular openings. The outlet openings 8 are preferably evenly distributed on the surface of the carrier disc 7, and each outlet opening may be spaced apart from an adjacent outlet opening by a distance of 2.5 mm. However, the distance may be between 0.5 mm and 3 mm. The pattern of the opening distribution may look like a grid or a matrix.

[0191] In the proposed embodiment, the outlet opening 8 may have a diameter set at about 1 mm. However, the diameter of the outlet opening may be between 0.4 mm and 3 mm, preferably between 0.5 mm and 1.3 mm.

[0192] In a variant embodiment not shown, the outlet opening is an oval hole.

[0193] The manufacturing process of a carrier plate with a specific outlet opening distribution can be accomplished using a stamping technique of a metal foil. This type of technique uses a die to stamp the material through a matrix. However, other techniques known to those skilled in the art may be used.

[0194] The proposed carrier tray 7 of FIGS. 4 a , 4 b and 4 c may comprise between 50 and 150 outlet openings 8 , the opening area ratio of the carrier tray being preferably higher than 4%.

[0195] The open area ratio is defined as the ratio between the sum of the surfaces of the holes and the surface of the carrier disc. The formula is as follows:

[0196]

[0197] Ros = Opening area ratio

[0198] Sh = hole surface

[0199] Sd = carrier surface

[0200] In the present invention, the initial requirement is to The disposable capsule is extracted in the machine to obtain a filter-like coffee with as little crema as possible. If some crema is produced in some cases, it is expected to disappear after 2 minutes.

[0201] The following table (Table 1) shows that not only the number of outlet openings 8 (also called holes) is important, but also the size of the holes and the size of the carrier disc, resulting in an opening area ratio.

[0202] The test was carried out on a carrier plate with a diameter of approximately 30 mm.

[0203] The data given in Table 1 are shown as follows.

[0204] Tests 1, 2 and 5 to 7 were carried out with a number of holes higher than 50 and an open area ratio higher than 4%. The results were considered satisfactory since the resulting coffee beverage did not show any residual crema after 2 minutes of extraction.

[0205] In Test 3, when the number of holes was less than 50 and the open area ratio was less than 4%, the extracted coffee contained crema that did not disappear after 2 minutes. The final extracted coffee was similar to coffee obtained by high pressure extraction of a closed capsule.

[0206] In Test 4, when the number of holes was lower than 50 (e.g., 2) and the open area ratio was higher than 4%, coffee extraction was possible, but the coffee was unsatisfactory due to coffee particles in the cup due to technical problems associated with the filter piercing the tearing surface of the machine. This extraction process is similar to conventional high-pressure closed capsule extraction, in which a capsule element (here, a filter) is torn on the tearing surface of an extraction plate of a beverage machine.

[0207]

[0208] Table 1

[0209] Reference Figure 5 , a table is given showing, for different carrier plate versions and the resulting extracted coffee (picture of the coffee cup seen from above), at different times, t0 corresponding to the end of extraction, t0+1 min corresponding to 1 minute after the end of extraction, t0+2 min corresponding to 2 minutes after the end of extraction, and t0+5 min corresponding to 5 minutes after the end of extraction.

[0210] It can be seen that the carrier disc corresponding to the reference and the carrier disc with more than 50 holes shows no crema or very little crema remaining in the cup at t0+1 minutes.

[0211] The carrier plate comprising 42 holes (V2.1.7) shows residual crema in the coffee at t0+5 minutes and therefore does not correspond to the expected filter-like coffee. In the machine, the carrier tray cannot be retained for the specific purpose of making filter-like coffee using disposable capsules.

[0212] According to the above results ( Figure 5 and Table 1), the carrier tray preferably comprises between 70 and 120 outlet openings, and most preferably comprises between 85 and 110 outlet openings.

[0213] As for the opening area ratio of the carrier tray, the opening area ratio may be higher than 4%, and is preferably between 4% and 15%, and more preferably between 5% and 12%.

[0214] For example, openings with a diameter of 0.3 mm are evenly distributed on a carrier disk with a diameter of approximately 30 mm.

[0215] · 5% open area ratio produces about 200 holes,

[0216] 10% open area ratio produces about 995 holes,

[0217] An open area ratio of 15% results in approximately 1493 holes.

[0218] Turning to Figs. 6a and 6b, the proposed carrier tray 7 is shown together with different orientations of the carrier tray relative to the tearing surface 12 of the extraction chamber of the beverage preparation device.

[0219] The carrier disc 7 shown may have a diameter of approximately 30 mm and comprise 96 outlet openings distributed over the entire surface of the carrier disc, in addition to the void space 10 which is free of outlet openings 8 at a distance of approximately 1 mm on its periphery.

[0220] The open area ratio of the carrier tray is about 9.3%.

[0221] In addition to the parameters discussed above, and as explained, the capsule 1 incorporating said particular carrier tray 7 is intended to be extracted in a beverage preparation device or machine (not shown).

[0222] The beverage preparation device (not shown) comprises a fluid dispensing device capable of supplying a quantity of fluid, such as water, to the capsule at a pressure between 0.1 bar and 20 bar, and a brewing chamber comprising a first part for holding the capsule and a second part for closing the brewing chamber. The second part of the brewing chamber comprises an extraction plate for engaging the replaceable capsule at the second end of the side wall when the brewing chamber holding the capsule is closed, the extraction plate comprising a tearing surface having a pyramidal element facing the second end of the capsule in use.

[0223] Therefore, during the extraction process of the capsule of the invention, the cover of the capsule is removed before inserting the capsule inside the brewing chamber of the beverage preparation device. The capsule and more specifically the carrier disc 7 then faces the tearing surface (in the form of a cone element) of the extraction plate of the beverage preparation device.

[0224] During the extraction process, water is injected into the capsule and mixed with the coffee components arranged in the inner space of the capsule. Since the cover has been removed, the extraction of the coffee components is an extraction performed at a pressure below 8 bars, more preferably below 5 bars.

[0225] The coffee beverage then passes through the filter and is intended to flow out of the capsule through the outlet opening.

[0226] Even if the carrier tray does not interact tearingly with the tearing surface of the extraction plate during extraction, it is important that the extracted coffee is not prevented from leaving the carrier tray and is not affected by the nearby tearing surface of the extraction plate.

[0227] In the proposed outlet opening distribution pattern, less than 10% of the outlet openings 8 of the carrier disc 7 directly face the tearing surface of the extraction plate.

[0228] The pattern is configured such that the above features are independent of the angular positioning of the carrier disc relative to the tearing surface of the extractor plate.

[0229] FIG. 6 b specifically shows a transparent overlay of the tear surfaces of the carrier disc and the extractor plate presenting the proposed hole distribution pattern of FIG. 6 a at three different angular positions (0°, 20° and 30° respectively).

[0230] For each angular position of the carrier disc 7 , the number of blocked holes is counted: 4 holes are blocked at 0°, 8 holes are blocked at 20° and 6 holes are blocked at 30°.

[0231] Regardless of the angular position of the carrier disc relative to the tearing surface of the extraction plate, an optimized and regular flow of the extracted coffee is obtained due to the low number of blocked holes (less than 10%).

[0232] As mentioned above, the number of openings 8 of the carrier disc 7 and the diameter of each of these openings 8 are important for achieving no residual crema or at least a particularly small amount of crema in the resulting beverage. It is therefore desirable to produce a particularly large number of these openings 8 in the carrier disc 7 with high precision, i.e. in a precise manner. Figures 7 to 22 The following embodiment of the method explained achieves this object in a very easy manner.

[0233] Figure 7 A sheet material 70 from which a carrier disc 7 with an outlet opening 8 can be obtained is shown. As shown, a cutting device (not shown) has cut the sheet material to obtain a first set 8.1 of outlet openings 8. The first set 8.1 is represented in black. As shown, the outlet openings of the first set 8.1 may be distributed non-uniformly, for example, in such a way that the first set 8.1 includes at least a first subset 8.11 of outlet openings and a second subset 8.12 of outlet openings, wherein the distance between the subsets 8.11 and 8.12 and the distance between each other may be greater than the distance between adjacent outlet openings of the same subset. For example, in each of the subsets 8.11 and 8.12, the corresponding outlet openings may be evenly distributed. In other words, the non-uniform distribution of the outlet openings of the first set 8.1 may be affected by the distance between the subsets 8.11 and 8.12. The outlet openings in the first set 8.1 may be arranged according to a matrix or a grid, such as along a plurality of columns and a plurality of rows.

[0234] like Figure 7 As shown, the sheet material 70 comprises a (first) alignment opening 71. In this embodiment, the alignment opening 71 has been cut by a cutting device. For example, by cutting the sheet material 70 to obtain the first set 8.1, the cutting device simultaneously cuts the sheet material 70 to obtain the alignment opening 71. In an alternative embodiment, the alignment opening 71 can be prefabricated in the sheet material 70 so that the alignment opening 71 can be produced without a cutting device. The alignment opening 71 is not limited to a specific shape. For example, the alignment opening 71 has a circular shape and / or has a diameter that is larger than the diameter of each of the outlet openings 8.

[0235] Figure 8 A sheet material 70 is shown having a second set 8.2 of outlet openings 8. The second set 8.2 is indicated by oblique hatching. After the sheet material 70 has been cut to obtain the first set 8.1, as shown in FIG. Figure 7As shown, the sheet material 70 and the first set 8.1 can be moved in a direction 75 along a defined distance relative to the cutting device and then stopped. That is, the sheet material 70 can be moved intermittently. Then, in an alignment step, an alignment element 101 (for example in the form of a pin) that can be part of the cutting device is moved to extend through the first alignment opening 71. Thereby, the first set 8.1 is accurately aligned (centered, positioned, etc.) relative to the cutting device. In an optional step before alignment through the alignment opening 71, a pre-alignment of the alignment opening 71 relative to the alignment element 101 can be performed. For example, an optical device can (automatically) measure the distance between the alignment opening 71 and the alignment element 101, whereupon the sheet material 70 is advanced along this distance so that the alignment opening 71 is approximately flush with the alignment element 101. In other words, the pre-alignment of the sheet material relative to the alignment element can be performed by (automatic) visual control.

[0236] After the alignment step, the cutting device cuts the sheet material 70 to obtain a second set 8.2. As shown, at least a portion of the second set 8.2 may preferably be adjacent to the first set 8.1, so that at least a portion of the outlet openings of the first set 8.1 and at least a portion of the outlet openings of the second set 8.2 form a uniformly distributed set of outlet openings. As shown, the second set 8.2 may have the same hole pattern as the first set 8.1. Therefore, the second set 8.2 may also include at least a first subset 8.21 of outlet openings and a second subset 8.22 of outlet openings, wherein the subset 8.21 and the subset 8.22 may be spaced a certain distance from each other. As shown, the second subset 8.22 may be arranged between the subset 8.11 and the subset 8.12 of the first set 8.1.

[0237] like Figure 8 As shown, the sheet material 70 may include a second alignment opening 72. The second alignment opening 72 may have been cut by a cutting device. For example, by cutting the sheet material 70 to obtain the second set 8.2, the cutting device simultaneously cuts the sheet material 70 to obtain the second alignment opening 72. In an alternative embodiment, the alignment opening 72 may be prefabricated in the sheet material 70 so that the alignment opening 72 can be produced without a cutting device. The alignment opening 72 may be the same as the alignment opening 71. The alignment opening 72 is not limited to a specific shape. For example, the alignment opening 72 has a circular shape and / or has a diameter that is larger than the diameter of each of the outlet openings 8.

[0238] Fig. 9 A sheet material 70 is shown having a third set 8.3 of outlet openings 8. The third set 8.3 is represented by hatching opposite to the hatching representing the second set 8.2. After the sheet material 70 has been cut to obtain the second set 8.2, as shown in FIG. Figure 8As shown, the sheet material 70 and the first set 8.1 and the second set 8.2 can be moved in a direction 75 along a defined distance relative to the cutting device and then stopped. Then, in an alignment step, the alignment element 101 is moved to extend through the first alignment opening 71. Thereby, the first set 8.1 and the second set 8.2 are accurately aligned (centered, etc.) relative to the cutting device. In an optional step before alignment, such as by using the above-mentioned optical device, a pre-alignment of the alignment opening 71 relative to the alignment element 101 can be performed, for example similar to the pre-alignment of the alignment opening 71.

[0239] After the alignment step, the cutting device cuts the sheet material 70 to obtain a third set 8.3. As shown, at least a portion of the third set 8.3 may preferably be adjacent to the second set 8.2, so that at least a portion of the outlet openings of the second set 8.2 and at least a portion of the outlet openings of the third set 8.3 and / or the first set 8.1 form a uniformly distributed set of outlet openings. As shown, the third set 8.3 may have a hole pattern that is the same as the hole pattern of the first set 8.1 and the second set 8.2, respectively. Therefore, the third set 8.3 may also include at least a first subset 8.31 of outlet openings and a second subset 8.32 of outlet openings, wherein the subset 8.31 and the subset 8.32 may be spaced a distance from each other. As shown, the second subset 8.32 may be arranged between the subset 8.11 and the subset 8.22.

[0240] like Fig. 9 As shown, the sheet material 70 may include a third alignment opening 73. The third alignment opening 72 may have been cut by a cutting device. For example, by cutting the sheet material 70 to obtain the third set 8.3, the cutting device simultaneously cuts the sheet material 70 to obtain the third alignment opening 73. In an alternative embodiment, the alignment opening 73 may be prefabricated in the sheet material 70 so that the alignment opening 73 can be produced without a cutting device. The alignment opening 73 may be the same as the alignment opening 71 and the alignment opening 72, respectively. The alignment opening 73 is not limited to a specific shape. For example, the alignment opening 73 has a circular shape and / or has a diameter that is larger than the diameter of each of the outlet openings 8.

[0241] Repeatable reference Figures 7 to 9 The steps described to provide an additional set of outlet openings are as follows:

[0242] - moving the sheet material 70 and thus the obtained set by a defined distance in direction 75 relative to the cutting device;

[0243] - stopping the sheet material 70;

[0244] - aligning the obtained set relative to the cutting means by means of an alignment element 101 which is moved so as to extend through an alignment opening (obtained, for example, in a preceding cutting step); and

[0245] - cutting the sheet material 70 having the set of outlet openings thus aligned by means of a cutting device,

[0246] To obtain a further set of outlet openings including the aligned openings.

[0247] The sheet material 70 and the first set 8.1 are moved relative to the cutting device to produce the second set 8.2 (i.e. Figure 7 Arrangement in Figure 8 The distance of the arrangement in the figure) may correspond to (i.e. be equal to) the sheet material 70 and the first set 8.1 and the second set 8.2 are moved relative to the cutting device to produce the third set 8.3 (i.e. from Figure 8 Arrangement in Fig. 9 In other words, in order to obtain the first set 8.1 to the third set 8.3, the sheet material 70 may be intermittently moved along equal distances (ie substantially the same distances as each other) relative to the cutting device.

[0248] Fig.10 A sheet material 70 is shown with a fourth set 8.4 of outlet openings 8. The fourth set 8.4 is indicated in black outline and white. After the sheet material 70 has been cut to obtain the third set 8.3, as shown in FIG. Figure 8 As shown, the sheet material 70 and the set 8.1, 8.2, 8.3 can be moved in direction 75 along a defined distance relative to the cutting device and then stopped. Then, in an alignment step, a further alignment element 102 (e.g. a pin or an alignment element identical to the alignment element 101) is moved to extend through the first alignment opening 71. Thereby, the set 8.1, 8.2, 8.3 is accurately aligned (centered, etc.) relative to the cutting device. In an optional step prior to alignment, such as by using an optical device as described above, a pre-alignment of the alignment opening 71 relative to the alignment element 102 can be performed, for example similar to the pre-alignment of the alignment opening 71 described above.

[0249] After the alignment step, the cutting device cuts the sheet material 70 to obtain a fourth set 8.4. As shown, at least a portion of the fourth set 8.4 may preferably be arranged between the outlet openings of the first set 8.1, such as the first subset 8.11, so that at least a portion of the outlet openings of the first set 8.1 and at least a portion of the outlet openings of the fourth set 8.4 and / or the third set 8.3 form a uniformly distributed set of outlet openings. As shown, the fourth set 8.4 may be obtained between the first subset 8.31 and / or the first subset 8.21 on the one hand and the second subset 8.32, the second subset 8.22 and / or the second subset 8.12 on the other hand. In other words, the outlet openings of the first set 8.1 may be surrounded by a portion of the sheet material 70, wherein the cutting device cuts this portion to obtain at least one outlet opening of the fourth set 8.4 arranged between the outlet openings of the first set 8.1. In particular, the outlet openings 8 of the fourth set 8.4 arranged between the outlet openings 8 of the first set 8.1 may be spaced apart from adjacent openings 8 of the first set 8.1 by a distance of between 0.5 mm and 3 mm and more preferably between 1 mm and 3 mm. Adjacent outlet openings 8 of the first set 8.1 may be spaced apart from each other by a distance greater than the distance between the outlet openings 8 of the fourth set 8.4 (arranged between the outlet openings 8 of the first set 8.1) and the openings 8 of the first set 8.1 (adjacent to said outlet openings 8 of the fourth set 8.4).

[0250] The fourth set 8.4 is not limited to a specific hole pattern. The hole pattern of the fourth set 8.4 may be different from the hole pattern of at least the first set 8.1. As shown, the outlet openings of the fourth set 8.4 may be (completely) evenly distributed, for example in such a way that the fourth set 8.4 does not include any subsets spaced apart from each other by a distance greater than the distance between adjacent outlet openings of the fourth set 8.4. The outlet openings in the fourth set 8.4 may be arranged according to a matrix or grid, such as along a plurality of columns and a plurality of rows, wherein the number of rows is preferably greater than the number of columns.

[0251] The method is not limited to obtaining the fourth set 8.4 after having obtained the third set 8.3. For example, the fourth set 8.4 may be obtained directly after having obtained the first set 8.1 and / or the second set 8.2, such that the fourth set 8.4 is the second set of outlet openings or the third set of outlet openings, respectively.

[0252] Fig.11 A sheet material 70 having a fifth set 8.5 of outlet openings 8 is shown. The fifth set 8.5 is indicated by vertical hatching. After the sheet material 70 has been cut to obtain the fourth set 8.4, as shown in FIG. Fig.10As shown, the sheet material 70 and the sets 8.1 to 8.4 can be moved in the direction 75 along a defined distance relative to the cutting device and then stopped. Then, in an alignment step, the alignment element 102 is moved to extend through the second alignment opening 72. Thereby, the sets 8.1 to 8.4 are accurately aligned relative to the cutting device. In an optional step before alignment, such as by using an optical device as described above, a pre-alignment of the alignment opening 72 relative to the alignment element 102 can be performed, for example similar to the pre-alignment of the alignment opening 71 described above.

[0253] After the alignment step, the cutting device cuts the sheet material 70 to obtain the fifth set 8.5. As shown, at least a portion of the fifth set 8.5 can preferably be arranged between the outlet openings of the second set 8.2 (such as the first subset 8.21), so that at least a portion of the outlet openings of the fifth set 8.5 and at least a portion of the outlet openings of the second set 8.1 and / or the first set 8.1 form a uniformly distributed set of outlet openings. As shown, the fifth set 8.5 can be obtained between the first subset 8.31 on the one hand and the second subset 8.32, the second subset 8.22 and / or the second subset 8.12 on the other hand. As shown, the fifth set 8.5 can have the same hole pattern as the fourth set 8.4. In other words, the outlet opening of the second set 8.2 can be surrounded by a portion of the sheet material 70, wherein the cutting device cuts this portion to obtain at least one outlet opening of the fifth set 8.5 arranged between the outlet openings of the second set 8.2.

[0254] Fig.12 A sheet material 70 having a sixth set 8.6 of outlet openings 8 is shown. The sixth set 8.6 is indicated by horizontal hatching. After the sheet material 70 has been cut to obtain the fifth set 8.5, as shown in FIG. Fig.11 As shown, the sheet material 70 and the sets 8.1 to 8.5 can be moved in the direction 75 along a defined distance relative to the cutting device and then stopped. Then, in an alignment step, the alignment element 102 is moved to extend through the third alignment opening 73. Thereby, the sets 8.1 to 8.5 are accurately aligned relative to the cutting device. In an optional step before alignment, such as by using an optical device as described above, a pre-alignment of the alignment opening 73 relative to the alignment element 102 can be performed, for example similar to the pre-alignment of the alignment opening 71 described above.

[0255] After the alignment step, the cutting device cuts the sheet material 70 to obtain a sixth set 8.6. As shown, at least a portion of the sixth set 8.6 can preferably be arranged between the outlet openings of the third set 8.3 (such as the first subset 8.31), so that at least a portion of the outlet openings of the fifth set 8.5 and at least a portion of the outlet openings of the third set 8.3 and / or the second set 8.2 form a uniformly distributed set of outlet openings. As shown, the sixth set 8.6 can be obtained between a portion of the first subset 8.31 on the one hand and between the second subset 8.32, the second subset 8.22 and / or the second subset 8.12 on the other hand. In other words, the outlet openings of the third set 8.3 can be surrounded by a portion of the sheet material 70, wherein the cutting device cuts this portion to obtain at least one outlet opening of the sixth set 8.6 arranged between the outlet openings of the third set 8.3.

[0256] As shown, the sixth set 8.6 may have the same hole pattern as the fourth set 8.4 and / or the fifth set 8.5.

[0257] Repeatable reference Figures 10 to 12 The steps described to provide an additional set of outlet openings are as follows:

[0258] - moving the sheet material 70 and thus the obtained set by a defined distance in direction 75 relative to the cutting device;

[0259] - stopping the sheet material 70;

[0260] - aligning the obtained set relative to the cutting means by means of an alignment element 102 which is moved so as to extend through an alignment opening (obtained, for example, in one of the cutting steps for obtaining the first to third sets); and

[0261] - cutting the sheet material 70 having the set of outlet openings thus aligned by means of a cutting device,

[0262] to obtain an additional set of outlet openings.

[0263] The sheet material 70 and the fourth set 8.4 are moved relative to the cutting device to produce a fifth set 8.5 (i.e. Fig.10 Arrangement in Fig.11 The distance of movement of the arrangement in (i.e., the distance of movement of the sheet material 70 having the fourth set 8.4 and the fifth set 8.5 relative to the cutting device to produce the sixth set 8.6 (i.e., from Fig.11 Arrangement in Fig.12 In other words, in order to obtain the fourth set 8.4 to the sixth set 8.6, the sheet material 70 may be intermittently moved along equal distances (ie substantially the same distances as each other) relative to the cutting device.

[0264] To obtain a collection of outlet openings, the sheet material 70 may be moved intermittently along different distances. For example, a sheet material 70 having one or more collections 8.1 to 8.3 is moved relative to the cutting device to produce a fourth collection 8.4 (e.g., from Fig. 9 Arrangement in Fig.10 The (second) distance of movement of the arrangement in the arrangement may be greater than the (first) distance, and the sheet material 70 and the first set 8.1 are moved relative to the cutting device along the (first) distance to produce the second set 8.2, or the sheet material 70 having the first set 8.1 and the second set 8.2 is moved relative to the cutting device along the (first) distance to produce the third set 8.3.

[0265] In particular, the first set 8.1 and preferably the second set 8.2 and the third set 8.3 may be obtained by using a first cutting station of the cutting device, and the fourth set 8.4 and preferably the fifth set 8.5 and the sixth set 8.6 may be obtained by using a second cutting station of the cutting device, which second cutting station is different from the first cutting station and / or is spaced a distance from the first cutting station. In particular, by moving the sheet material 70 along a second distance, one or more sets of outlet openings 8 obtained in the first cutting station are moved to the second cutting station, where one or more further sets of outlet openings 8 are obtained. Thus, the first alignment element 101 may be arranged to align (center, position, etc.) at least the first set 8.1 relative to the first cutting station, and the second alignment element 102 may be arranged to align at least the first set 8.1 relative to the second cutting station. The cutting stations may be arranged along the moving direction of the sheet material.

[0266] Figures 13 to 18 An embodiment with intermittent movement of sheet material with different distances is shown. In each interruption of this intermittent movement, at least one cutting step (and preferably an alignment step) is performed to obtain two corresponding sets of outlet openings, such as Figures 13 to 18 As shown, one set is cut by the first cutting station and the other set is cut by the second cutting station. Figures 13 to 18 In FIG. 8 , the sets 8 . 1 to 8 . 6 of outlet openings 8 are shown in the form of boxes and in a schematic and simplified manner. A box corresponds to a subset or a set if the set does not have a plurality of subsets.

[0267] like Figures 13 to 15 As shown, the sheet material 70 is cut by a cutting device, in particular by a first cutting station, to obtain a first set 8.1 to a third set 8.3, respectively, as described above with reference to Figures 7 to 9 At the same time, the sheet material 70 is cut by a cutting device, in particular by a second cutting station, to obtain a fourth set 8.4 to a sixth set 8.6, respectively. Fig.13 and Fig.14 Between the states shown and in Fig.14 and Fig.15 Between the states shown, the sheet material 70 is moved the same distance relative to the cutting device.

[0268] like Figures 16 to 18 As shown, the sheet material 70 is cut by a cutting device, in particular by a second cutting station, to obtain a fourth set 8.4 to a sixth set 8.6 of outlet openings of the carrier disc 7, respectively, as described above with reference to Figures 10 to 12 At the same time, the sheet material 70 is cut by a cutting device, in particular by a first cutting station, to obtain further sets of outlet openings at least partially for further carrier discs 7. These further sets of outlet openings are respectively as described above with reference to Figures 7 to 9 As explained above. Fig.15 and Fig.16 Between the states shown, the sheet material 70 and the first set 8.1 to the third set 8.3 are greater than Fig.13 and Fig.14 The status shown is between Fig.14 and Fig.15 By this greater distance, the first set 8.1 to the third set 8.3 are positioned relative to the second cutting station in order to obtain the fourth set 8.4 to the sixth set 8.6. Fig.16 and Fig.17 Between the states shown and in Fig.17 and Fig.18 Between the states shown, the sheet material 70 is moved the same distance relative to the cutting device.

[0269] like Fig.18 As shown, at least two groups of alignment openings may be arranged in a row extending parallel to the moving direction 75 of the sheet material 70. Each group may be provided for a first set and a second set of outlet openings of one or more carrier plates. Each of these groups comprises at least one corresponding alignment opening 71, preferably two or more corresponding alignment openings 71 to 73. In each group, the corresponding alignment openings 71 to 73 may be arranged equidistantly. The distance between adjacent groups may be different from (e.g., greater than) the distance between adjacent alignment openings in the same group.

[0270] In an optional step of the method, a carrier disc 7 comprising at least the set 8.1 to the set 8.6 is obtained. According to one embodiment, an alignment element is used to extend through one of the one or more alignment openings, such as through the alignment opening 71, in order to align the set 8.1 to the set 8.6 relative to the cutting device, in particular relative to the third cutting station of the cutting device. The cutting device, such as the third cutting station, then cuts the sheet material 70 in such a way that the carrier disc 7 comprises the thus aligned set 8.1 to the set 8.6 of the outlet openings 8 to obtain the carrier disc 7.

[0271] The sheet material 70 may be cut to obtain a plurality of at least two sets of outlet openings 8 for a corresponding plurality of carrier trays. The sheet material 70 thus cut may then be brought into a state suitable for transport, such as being rolled up to form a sheet roll, such as Fig.21 A sheet roll 76 is shown. Then, a sheet roll can be provided or supplied and a plurality of carrier trays each comprising a plurality of at least two sets of outlet openings 8 can be obtained from the sheet material 70. In other words, the result of the method for obtaining at least outlet openings can be a preform for a plurality of carrier trays.

[0272] Fig.19 An example of a sheet material 70 is shown. As shown, one or more aligned openings may be arranged in a row extending parallel to the moving direction of the sheet material. As shown, a plurality of carrier trays 8 can be produced or obtained from the sheet material 70. The plurality of carrier trays 8 may be obtained from the sheet material 70 in such a way that after obtaining the plurality of carrier trays 8 from the sheet material 70, corresponding cut-out portions are arranged in the sheet material 70 in the form of a matrix or grid, such as with a plurality of rows (e.g., at least two, preferably at least five, more preferably at least ten), wherein the rows extend parallel to the moving direction of the sheet material 70.

[0273] The sheet material 70 may include one or more first rows, the one or more first rows respectively including a plurality of alignment openings 71 to 73 and respectively extending parallel to the moving direction of the sheet material 70, and one or more second rows respectively including a plurality of outlet opening sets of a plurality of carrier discs and respectively extending parallel to the moving direction of the sheet material 70. Preferably, the number of first rows is less than the number of second rows. The number of first rows may be two. The number of second rows may be at least 10. The plurality of alignment openings 71 to 73 (e.g. in each of the first rows) may be arranged in groups (e.g. depending on the number of cutting (such as punching) steps during the first production step, i.e. the step of obtaining the set of outlet openings before obtaining the carrier disc in the second production step), for example so that each of these groups includes at least one corresponding alignment opening 71, preferably two or more corresponding alignment openings 71 to 73. In each group, the corresponding alignment openings 71 to 73 may be arranged equidistantly. The distance between adjacent groups may be different from (e.g. greater than) the distance between adjacent alignment openings in the same group.

[0274] like Fig. 20 As shown, the sheet material 70 may be provided as a sheet roll 76 , wherein a cutting device may cut a portion of the unrolled (ie, not curved but, for example, straight) sheet material 70 .

[0275] The method may further comprise the step of providing a filter element 9, such as the filter element 9 described above.

[0276] At least a portion of the sheet material 70 may be arranged between at least a portion of the cutting device and the capsule body 2, in which the carrier disc 7 and optionally the filter element 9 will be positioned. For example, the sheet material unwound from a sheet roll 76 may be arranged between the cutting device and the capsule body 2 (seen from the side).

[0277] The method is not limited to a specific type of cutting or cutting device. The cutting device may be suitable for cutting sheet material to obtain a large number of outlet openings, such as 1200 outlet openings, in a single step. The cutting device may include at least two cutting stations, wherein each station in these stations may be suitable for cutting sheet material to obtain at least 100 outlet openings in a single step (in a single cutting step, such as during a single stroke), preferably obtaining outlet openings between 200 and 400. In one embodiment, the cutting device is a punching device. For example, the punching device may include a first punching station for cutting sheet material 70 to obtain at least a set 8.1 and a second punching station for cutting sheet material 70 to obtain at least a set 8.4. Each punching station in the punching station may include a punching machine, which is designed to obtain a hole pattern of a corresponding set of outlet openings. The punching machine may include a plurality of punching elements, which correspond to the outlet openings of the corresponding set of outlet openings in quantity and arrangement. Each of the punching stations may include a die into which at least a portion of the punch may enter after passing through the sheet material 70. The die may include a plurality of die elements corresponding in number and arrangement to the outlet openings and / or punching elements of the respective set of outlet openings. The punching device may include a punching station dedicated to cutting the sheet material 70 to obtain a carrier disc 8 comprising at least the set 8.1 and at least the set 8.4.

[0278] Fig.21 An example of a punching element 110 used in an embodiment of the method to obtain one of the outlet openings 8 is shown. The punching element 110 is arranged opposite to a die 111, into which at least a portion of the punching element 110 may enter after passing through the sheet material 70. Before the punching element 110 passes through the sheet material 70 to cut it, the sheet material 70 may be arranged between the die 111 and the punching element 110. The punching station may include a punching template 112 (such as in the form of a plate), wherein the sheet material 70 may be arranged below the punching template 112 or between the punching template 112 and the die 111.

[0279] Fig. 22 The example shows the use of Fig.21The punching process of the arrangement. As shown in the figure, the punching process is carried out in four stages (a) to (d). In the first stage (a), the punching element 110 contacts the sheet material 70, thereby deforming the sheet material 70. Then, in stages (b) and (c), the sheet material 70 is cut by the punching element 70. Finally, in stage (d), the tension in the material is so great that the sheet element 70 breaks along the contour of the cut. The cut-out piece (the so-called punching block) of the sheet element 70 is discharged from the sheet element 70, in particular discharged downwardly, for example discharged into the die 111. When the punching element 110 moves upward again, it may happen that the sheet element 70 is pulled together. In this case, the punching template 112 can be arranged to release the sheet material 70 from the punching element 110.

[0280] Although the present invention has been described by way of example, it should be appreciated that variations and modifications may be made without departing from the scope of the invention as defined in the claims. In addition, if known equivalents exist for specific features, such equivalents should be incorporated as if explicitly mentioned in this specification.

[0281] References

[0282] 1 capsule

[0283] 2 capsule body / 2a side wall

[0284] 3 Base wall

[0285] 4 Flange

[0286] 5. Cover

[0287] 6 Pull Tab

[0288] 7 Carrying plate

[0289] 8 Exit opening

[0290] 8.1 First set of outlet openings

[0291] 8.11 The first subset of the first set

[0292] 8.12 Second subset of the first set

[0293] 8.2 Second set of outlet openings

[0294] 8.21 The first subset of the second set

[0295] 8.22 The second subset of the second set

[0296] 8.3 The third set of outlet openings

[0297] 8.31 The first subset of the third set

[0298] 8.32 The second subset of the third set

[0299] 8.4 The fourth set of exit openings

[0300] 8.5 Fifth set of exit openings

[0301] 8.6 Sixth set of exit openings

[0302] 9 Filters

[0303] 10 Void Space

[0304] 11 Mechanical deformation / curling

[0305] 70 Sheet Material

[0306] 71 First alignment opening

[0307] 72 Second alignment opening

[0308] 73 Third alignment opening

[0309] 75 Sheet moving direction

[0310] 76 Sheet Roll

[0311] 101 First alignment element

[0312] 102 Second alignment element

[0313] 110 Stamping components

[0314] 111 Mould

[0315] 112 Punching template

Claims

1. A method for obtaining at least an outlet opening (8) of a carrier tray (7), said carrier tray being arrangeable in an inner space of a capsule (1) for preparing a beverage, wherein said outlet opening (8) is adapted to allow the prepared beverage to flow out of said inner space towards the outside of said capsule (1) when said capsule (1) is used in a beverage preparation device, wherein said method comprises the following steps: providing a sheet material (70) from which said carrier disc (7) with said outlet opening (8) can be obtained, cutting the sheet material (70) by means of a cutting device to obtain a first set of outlet openings (8), aligning said first set of outlet openings relative to said cutting device by means of an alignment element (101) extending through an alignment opening (71) provided in said sheet material (70), cutting said sheet material (70) having said first set of outlet openings thus aligned by said cutting means to obtain said second set of outlet openings, and The sheet material (70) is intermittently moved along different distances relative to the cutting device.

2. The method according to claim 1, further comprising the steps of: aligning the set of outlet openings (8) relative to the cutting device by means of the alignment element (101) extending through a further alignment opening (72) provided in the sheet material (70), and The sheet material (70) having the set of outlet openings (8) thus aligned is cut by the cutting device to obtain a further set of outlet openings (8).

3. The method according to claim 1 or 2, further comprising the following steps: aligning the set of outlet openings (8) relative to the cutting device by means of a further alignment element (102) extending through the alignment opening (71) provided in the sheet material (70), and The sheet material (70) having the set of outlet openings (8) thus aligned is cut by the cutting device to obtain an additional set of outlet openings.

4. The method according to any of the preceding claims, wherein at least a portion of the outlet openings of one set of the outlet openings (8) are arranged between the outlet openings (8) of the respective other set of the outlet openings (8).

5. Method according to any of the preceding claims, further comprising the step of cutting the sheet material by means of the cutting device to obtain the aligned openings (71).

6. Method according to any of the preceding claims, wherein the aligned openings (71) are obtained in a cutting step for obtaining the first set of outlet openings.

7. The method according to any one of the preceding claims, further comprising the steps of: The sheet material is cut by the cutting device to obtain the carrier tray (7) such that the carrier tray (7) comprises the set of outlet openings (8).

8. Method according to claim 7, wherein a carrier disc (7) is obtained which is free of outlet openings (8) on its periphery over a distance of at least 1 mm, preferably between 0.5 mm and 2.5 mm and more preferably between 1 mm and 2 mm.

9. The method according to any one of the preceding claims, further comprising the steps of: aligning the set of outlet openings (8) relative to the cutting device by using an alignment element extending through the alignment opening (71) or through another alignment opening (72; 73) provided in the sheet material (70), and The sheet material (70) is cut by the cutting device to obtain the carrier tray (7) such that the carrier tray (7) comprises the set of outlet openings (8) thus aligned.

10. The method according to any one of the preceding claims, wherein the cutting device is a punching device, wherein: Preferably, cutting of said first set and said second set of outlet openings is performed by the same punch or by different punches, respectively.

11. A method according to any of the preceding claims, wherein the outlet openings (8) of one set of the outlet openings (8) are spaced apart from adjacent outlet openings (8) of another set of the outlet openings (8) by a distance between 0.5 mm and 3 mm and more preferably between 1 mm and 3 mm.

12. Method according to any of the preceding claims, wherein adjacent outlet openings (8) of the same set of outlet openings (8) are spaced apart from each other by a distance which is greater than a distance between adjacent outlet openings (8) of a different set of outlet openings.

13. A method according to any of the preceding claims, wherein the outlet opening (8) of the carrying plate (7) or the set of outlet openings (8) comprises between 50 and 150 outlet openings (8), preferably between 70 and 120 outlet openings (8), and more preferably between 85 and 110 outlet openings (8).

14. Method according to any of the preceding claims, wherein the outlet opening (8) has a diameter between 0.4 mm and 3 mm, preferably between 0.5 mm and 2 mm.

15. Method according to any of the preceding claims, wherein the thickness of the sheet material (70) is between 0.05 mm and 1.5 mm, preferably between 0.1 mm and 1 mm, most preferably between 0.2 mm and 0.8 mm.

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