Capsule with a lower fluid director member lying above integrally thermoformed raised portions of a base wall of a main capsule body

Abstract

A capsule (C) comprises a cup-shaped main capsule body (MCB) that has a base wall (BW) configured to be pierced at a lower piercing position (LPP), and a lower fluid director member (LF) disposed, wherein the lower fluid director member defines a plurality of outlet filtering openings (OFO) for passage of produced beverage therethrough, and wherein a plurality of raised portions (RP) are provided that define a plurality of outflow channels (OFC) therebetween arranged to direct produced beverage flow from the plurality of outlet filtering openings (OFO) towards said lower piercing position (LPP). According to the inventive thought the plurality of raised portions have been integrally formed by means of thermoforming, in the base wall. The lower fluid director member (LF) is positioned above the integrally formed raised portions (RP) of the base wall (BW).

Description

[0001] Title: Capsule with a lower fluid director member lying above integrally thermoformed raised portions of a base wall of a main capsule body.

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to capsules for containing a substance from which a beverage can be produced, in particular ones adapted to contain a single serving of a particulate substance, extractable by means of a fluid, like pressurized hot water, for preparing a beverage. Particularly the substance may be coffee powder for preparing a coffee, like espresso, cafe crema or filter coffee.

[0004] BACKGROUND TO THE INVENTION

[0005] Such capsules are well known in a variety of different embodiments, like Nespresso®, Dolce Gusto® and Cafissimo®.

[0006] US-7,543,527 shows a coffee capsule of the Cafissimo® type, that is known to comprise a cup-shaped main body, a distinctive bowl-shaped lower fluid collection director member, a distinctive inverted bowl-shaped upper fluid distribution director member, and a cover. A single-serve batch of coffee powder fills up a space inside the main body in between the collection director member and distribution director member.

[0007] The collection director member has a bowl-shape and is provided with a plurality of downwardly raised portions having the shape of annular segments. Once the collection director member has been inserted into the main body, the downwardly raised portions rest on a flat base wall of the main body, with the result that a plurality of outflow channels are created in between them, running radially inwards to a central longitudinal axis of the capsule and concentrically around this central longitudinal axis. Besides the downwardly raised portions, the collection director member is provided with a plurality of openings in upper wall portions that lie in between the downwardly raised portions and that open out into the thus created outflow channels. The center of the collection director member comprises a conically shaped recess, directed upwardly towards the space filled with the coffee powder.

[0008] The distribution director member has an inverted bowl-shape and is provided with a plurality of upwardly raised portions having the shape of annular segments. Once the distribution director member has been inserted in its upside down orientation into the main body, lower wall portions that lie in between the upwardly raised portions, create a plurality of inflow channels in between them, running radially inwards to a central longitudinal axis of the capsule and concentrically around this central longitudinal axis. The lower wall portions are provided with a plurality of openings that connect to the space filled with the coffee powder. The center of the distribution director member comprises a conically shaped recess, directed downwardly towards the space filled with the coffee powder.

[0009] At a start of a brewing cycle, a hollow injection inlet piercing member is pushed at a center position through the cover and starts to feed pressurized hot brewing water into a free space between the cover and the distribution director member. At a same time, an outlet piercing member is pushed at a center position through the base wall of the main body such that an outlet opening is formed therein. During brewing, the distribution director member serves as a filter and as a distributing means for spreading the injected water via the inflow channels over the entire upper surface of the badge of coffee powder. At a same time the conically shaped recess advantageously prevents that the hollow injection inlet piercing member may accidentally pierce through the distribution director member and then may come in direct contact with the coffee powder. This is important because otherwise it may get increasingly contaminated or even blocked for subsequent brewing cycles. After the brewing water has flown through the entire badge of coffee powder, it arrives in the outflow channels between the collection director member and the base wall of the main body, from where it can flow out of the capsule via the pierced outlet opening. The collection director member then serves both as a collecting means and as a filter for the prepared coffee beverage. At a same time the conically shaped recess advantageously prevents that the outlet piercing member may accidentally pierce through the collection director member and then may come in direct contact with the coffee powder. This is important because otherwise coffee powder itself may end up in the brewed coffee beverage.

[0010] A disadvantage hereof is that the capsule with its distinctive cup-shaped main body, bowl-shaped fluid collection director member, inverted bowl-shaped fluid distribution director member and cover is relative expensive to manufacture and requires relative large amounts of different materials for their manufacturing.

[0011] The slightly conical main body for example is known to be thermoformed out of multilayer composite plastic foil that is gas tight, whereas the more complex bowl-shaped fluid collection director member and inverted bowl-shaped distribution director member are injection moulded out of another type of plastic, and whereas the cover is punched out of multilayer composite plastic / aluminium foil. All those different manufacturing techniques bring along their own restrictions for the materials to be used.

[0012] Due to the use of all those different materials, a 100% recycling of the capsules after use is hardly possible. Furthermore, the use of different materials may complicate welding or glueing, and may lead to different thermal behaviours of the components during transportation, storage and use. Another disadvantage is that some of the brewed coffee beverage is going to remain behind inside the downwardly raised portions having the shape of annular segments of the bowl-shaped fluid collection director member. This may lead to problems with leakage, dirtying and mould starting to grow when the used capsule is thrown away or falls down into a collective trash bin of a brewing machine.

[0013] WO-2019 / 172759 shows an injection moulded capsule body. The base wall hereof on its top surface has concentric, radially spaced ring segment-shaped ribs that are integrally coinjection moulded as locally thicker base wall portions. The ribs are discontinuous in that they have gaps between them. The gaps connect with each other and form flow paths towards outlet openings. At the centre of the base wall there is an upwardly projecting co-injection moulded cone-shaped centre element. This centre element has slits in its circumference that form the outlet openings connecting to the flow paths between the ribs. A lower filter disc of micro-porous material or of non-woven fabric is positioned on top of the ribs and the centre element. A badge of substance from which a beverage can be extracted subsequently gets filled inside the capsule body on top of the lower filter disc, after which an upper filter disc of micro-porous material or of non-woven fabric is positioned above the badge and secured to an upper stepped edge of the capsule body's circumferential side wall. Finally, an aluminium or multi-layered synthetic plastics upper disc-shaped closure element is secured to an upper rim of the capsule body for closing off the upper opening, and an aluminium or multi-layered synthetic plastics lower disc-shaped closure element is secured to the outer surface of the base wall for closing off the slitted centre element.

[0014] A disadvantage hereof is that the capsule body with its distinctive capsule, body, upper and lower filter discs and upper and lower closure elements is relative expensive to manufacture and requires relative large amounts of different materials for their manufacturing, each requiring their own different manufacturing technique that brings along its own restrictions.

[0015] Due to the use of all those different materials, a 100% recycling of the capsules after use is hardly possible. Furthermore, the use of different materials may complicate welding or glueing, and may lead to different thermal behaviours of the components during transportation, storage and use.

[0016] Another disadvantage is that the base wall has large varying wall thicknesses. At the positions of the co-injection moulded concentric, radially spaced ring segment-shaped ribs the base wall automatically becomes much thicker than at the positions of the gaps in between them, and much thicker than at the position of the upwardly projecting co-injection moulded cone-shaped slitted centre element. Not only this requires additional injection moulding material, it also brings along difficulties during the injection moulding because it becomes more difficult to get the injection moulding material quickly and easily divided over the entire moulding space during injection, and after injection moulding because the cooling off of the manufactured capsule body shall take longer and may result in non-uniform crimp making it harder to remove the manufactured capsule body out of the mould.

[0017] BRIEF DESCRIPTION OF THE INVENTION

[0018] The present invention aims to overcome those disadvantages at least partly or to provide a usable alternative. In particular the present invention aims to provide a user-friendly single-serve beverage capsule that prevents outlet and / or inlet piercing members to come in direct contact with brewing substance, like coffee powder, while being economic to manufacture and while being well recyclable.

[0019] According to the present invention this aim is achieved by a capsule for containing a substance from which a beverage can be produced according to claim 1. The capsule comprises a cup-shaped main capsule body that has a base wall configured to be pierced at a lower piercing position by an outlet piercing member for forming an outlet opening, and a circumferential side wall, wherein the side wall and the base wall define a space with an open top end for containing said substance. The capsule further comprises a cover member attached to and covering the open top end of the main capsule body and configured to be pierced at an upper piercing position by an inlet piercing member for injection of a pressurized fluid, and a lower fluid director member disposed within a bottom portion of the main capsule body between the substance and the base wall. The lower fluid director member is dimensioned to correspond to an interior cross-sectional area of the bottom portion of the main capsule body, and defines a plurality of outlet filtering openings for passage of produced beverage therethrough. A plurality of raised portions are provided that define a plurality of outflow channels therebetween arranged to direct produced beverage flow from the plurality of outlet filtering openings towards said lower piercing position. According to the inventive thought the plurality of raised portions have been integrally formed by means of thermoforming in the base wall of the main capsule body, wherein the lower fluid director member that defines the plurality of outlet filtering openings for the passage of the produced beverage therethrough, is positioned above the integrally formed raised portions of the base wall of the main capsule body.

[0020] Thus the invention is based on the insight that immediately during manufacturing of the main capsule body by means of thermoforming upwardly raised base wall portions can be integrally formed in its base wall, such that a lower fluid director member with outlet filtering openings can be directly supported on top of those integrally formed upwardly raised base wall portions. By doing this a number of important advantages can be achieved.

[0021] First of all, the present invention makes it possible to design and use a rather straightforward and simple lower fluid director member that in terms of functionality merely needs to comprise a plurality of outlet filtering openings. This makes it possible to save on material and manufacturing costs for the lower fluid director member.

[0022] With this it is noted that the impact on material and manufacturing costs of the main capsule body may remain limited, because the main capsule body inevitably must be made with a three-dimensional shape, and even when having to include the integrally formed upwardly raised base wall portions, can still be manufactured by making use of thermoforming as desired manufacturing technique.

[0023] Second of all, it has now become possible to manufacture the main capsule body and the lower fluid director member out of such similar or even same types of materials that it has become much easier to recycle the capsule.

[0024] Third of all, due to the outflow channels being integrally co-manufactured in the base wall of the main capsule body itself and due to the lower fluid director member with its outlet filtering openings lying directly on top thereof, all produced beverage now can efficiently flow through the lower fluid director member into the created outflow channels. This prevents dripping or leakage to occur when the used capsule is thrown away or falls down into a collective trash bin of a brewing machine, and helps to prevent dirtying or mould starting to grow.

[0025] Fourth of all, the integrally formed upwardly raised base wall portions with the lower fluid director member directly supported on top thereof, advantageously are well able to create enough free space inside the created pattern of outflow channels that are defined between the base wall and the lower fluid director member, for said outlet piercing member to be pierced through a lower base wall part for forming an outlet opening therein, without running a risk of this outlet piercing member to accidentally also get pierced through the lower fluid director member itself.

[0026] Thus the capsule according to the present invention advantageously may be made compatible with already existing types of brewing machines where it is likewise foreseen to actively have an outlet piercing member get freshly pierced through a capsule's base wall at a start of a brewing cycle for forming an outlet opening therein. This for example goes for a Cafissimo® type of brewing machine.

[0027] It is noted that the co-injection moulded ring segment-shaped ribs according to WO- 2019 / 172759 that are integrally co-injection moulded as locally thicker base wall portions, are not the same as the now claimed raised base wall portions. In contrast thereto, according to the present invention, the raised base wall portions have been upwardly thermoformed compared to the rest of the base wall and thus have come to lie at a higher raised level than the rest of the base wall, while simultaneously the raised base wall portions when seen from below have become hollow. In other words, when seen from above the thermoformed capsule body's base wall due to having been thermoformed is profiled in that it comprises the pattern of thermoformed plurality of upwardly raised base wall portions defining the plurality of outflow channels therebetween, and when seen from below the thermoformed capsule body's base wall due to having been thermoformed is also profiled in that it comprises the inverse pattern of the hollows underneath the thermoformed plurality of upwardly raised base wall portions with the plurality of outflow channels forming downwardly lowered base wall portions therearound.

[0028] In a preferred embodiment the main capsule body including the base wall with its integral co-manufactured plurality of raised portions that define the plurality of outflow channels therebetween, has been manufactured by means of thermoforming out of sheet material, resulting in wall thicknesses of the thermoformed side wall and base wall that are thinner than the wall thickness of the sheet material. Thus advantageously a quick and reliable manufacturing method can be used for producing the main capsule bodies for the capsules according to the invention. The method of thermoforming such an array of reliefs as raised base wall portions in a bottom of a capsule out of sheet material automatically is able to accurately create a well-defined pattern of outflow channels between an inner side of that bottom of the capsule and a fluid director member serving as a filter / micropore sieve, so as not to block an outgoing flow of filtered beverage liquid by preventing blocking of the perforated lower fluid director member under pressure, and instead smoothly guide the produced beverage towards a reliable and well controllable freshly pierced outlet opening. Further it is noted that thermoforming is more cost effective for this type of coffee capsule than for example injection moulding or deep drawing.

[0029] The use of thermoforming out of sheet material further brings the advantage that easy switches can be made by starting the thermoforming on a different type of sheet material. For example the sheet material can be made single-layered or multi-layered, have varying wall thicknesses, be extruded with multiple different colours, be provided with all kinds of different printings, and / or surface finishes, etc. Also the thermoforming of the sheet material can easily be combined with in-mould labelling. The manufacturing of the main capsule bodies including the integrally formed raised base wall portions by means of the thermoforming makes it possible to manufacture the entire capsule quicker. Furthermore, for the thermoforming a less expensive mould is needed compared to injection moulding.

[0030] Wall thicknesses of the various sections of the capsule body as obtained after thermoforming may slightly differ. There where imposed thermoformed deformation of the sheet material is bigger, resulting wall thickness shall be prone to become thinner. It can be said though that the wall thicknesses of the various sections of the capsule body shall at least remain equal to or become thinner than the thickness of the original sheet material. In particular, an outwardly projecting flange that circumvents the open top end of the main capsule body and against which the cover member is to be attached, may well have a wall thickness after the thermoforming of the capsule body has been completed, that has remained substantially equal to the wall thickness of the original sheet material before the thermoforming, whereas the circumferential side wall and base wall of the capsule body may well have obtained wall thicknesses that are thinner, for example up to 30 or 40% thinner, after the thermoforming has been completed than the thickness of the original sheet material before the thermoforming.

[0031] In a preferred embodiment the capsule body may get thermoformed in two steps, wherein in a first thermoforming step the capsule body gets thermoformed in a basic cupshape with a flat base wall and a circumferential side wall, and wherein in a second thermoforming step the plurality of raised portions get thermoformed into the base wall. Thus a more precise result can be obtained.

[0032] For the first thermoforming step the sheet material can then be pre-heated, for example between 100-150 degrees, to then be forced into or over a mould having the basic cup-shape with the flat base wall, for example with the aid of vacuum forces.

[0033] For the second thermoforming step the thus obtained basic cup-shape with the flat base wall can be positioned in between a male and female die having the reliefs of the plurality of raised portions, for example without using vacuum forces. Instead of pre-heating the basic cup-shape, it is now advantageous to pre-heat the male and / or female die, for example between 100-150 degrees, such that the reliefs of the plurality of raised portions can be compression-thermoformed / heat-stamped into the base wall between the male and female die by moving them towards each other.

[0034] In a further preferred embodiment the capsule further comprises an upper fluid director member disposed within a top portion of the main capsule body between the substance and the cover member, wherein the upper fluid director member is dimensioned to correspond to an interior cross-sectional area of the top portion of the main capsule body, defines a plurality of inlet filtering openings for passage of injected pressurized fluid therethrough, and wherein the upper fluid director member is positioned in the top portion underneath the cover member to define an injection space to distribute injected fluid during beverage production towards the plurality of inlet filtering openings. This advantageously makes it possible to also design and use a rather straightforward and simple upper fluid director member that in terms of functionality merely needs to comprise a plurality of inlet filtering openings. This makes it possible to likewise save on material and manufacturing costs for the upper fluid director member.

[0035] It has now become possible to manufacture not only the lower fluid director member but also the upper fluid director member both out of similar or even same types of materials as the main capsule body.

[0036] The lower and upper fluid director members might even be almost the same, with the only difference being that the outer diameter of the upper fluid director member needs to be larger than the one of the lower fluid director member in the case of a slightly conical upwardly widening shape of the main capsule body. Even the size and distribution pattern of their outlet respectively inlet filtering openings can be kept the same.

[0037] The upper fluid director member positioned in the top portion underneath the cover member advantageously is well able to create enough free space between the cover and the upper fluid director member, for an inlet piercing member to be pierced through the cover member for injection of a fluid into the free space, without running a risk of this inlet piercing member to accidentally also get pierced through the upper fluid director member itself.

[0038] Thus the capsule according to the present invention advantageously may be made compatible with already existing types of brewing machines where it is likewise foreseen to not only actively have an outlet piercing member get freshly pierced through a capsule's base wall at a start of a brewing cycle for forming an outlet opening therein, but also at a same time actively have an inlet piercing member get freshly pierced through a capsule's cover member at a start of a brewing cycle for starting to inject fluid. This for example goes for a Cafissimo® type of brewing machine.

[0039] In a further preferred embodiment the lower and / or upper fluid director member may have a flat disc-shape that has been manufactured out of sheet material. Thus the fluid director members can easily be punched or otherwise cut out of a sheet material including a punching or otherwise cutting out of the filtering openings therein. This is quick, easy and economic. Furthermore it becomes more cost effective to also change the hole pattern of and / or diameters of the plurality of outlet filtering openings and / or inlet filtering openings if desired, for example for different coffee blends and / or flow time / restrictions, like for an espresso and / or an americano. No additional manufacturing moulds are needed for such different discs with different hole patterns and / or diameter.

[0040] In a further preferred embodiment the lower and / or upper fluid director member may have been welded or glued with an outer circumferential bottom surface portion against lower and / or upper inwardly projecting side wall edge(s) that is / are provided in the lower and / or upper portion of the main capsule body. In particular those inwardly projecting side wall edges may easily have been immediately co-manufactured by means of thermoforming in the circumferential side wall during manufacturing. The welding or glueing connection is deemed to form a reliable sealing connection, particularly when the lower and / or fluid director member have been made out of similar or even same types of materials as the main capsule body. In the case of welding a heat weld may already suffice, such that additional welding or glueing material can be dispensed with.

[0041] In an embodiment at least some of the raised portions of the base wall of the main capsule body may have been integrally formed by means of thermoforming with flat tops. Thus they may form support surfaces for the lower fluid director member to rest upon and lie against at least during a brewing cycle when pressurized fluid gets injected into the capsule, with the lower fluid director member remaining fully intact and not starting to crack or break or otherwise get damaged.

[0042] In addition thereto or in the alternative at least some of the raised portions of the base wall of the main capsule body have been integrally formed by means of thermoforming with rounded tops. Thus they may still form support surfaces for the lower fluid director member to rest upon and lie against at least during a brewing cycle when pressurized fluid gets injected into the capsule, with the lower fluid director member remaining fully intact and not starting to crack or break or otherwise get damaged, and with hardly any of the outflow openings therein getting closed off by them.

[0043] In a preferred embodiment the main capsule body may have been integrally formed by means of thermoforming with a wall thickness of the side wall becoming smaller than a wall thickness of the base wall with its integrally formed raised portions. Thus material can be saved for the circumferential side wall whereas the base wall with its raised portions can be kept strong enough to guarantee that the outflow channels are maintained even at high injection pressures during beverage production. This is particularly advantageous since the main capsule body gets thermoformed, because this makes it possible to start thermoforming the main capsule body out of a sheet material of uniform thickness, clamping it at a circumferential edge that is destined to form the flange of the capsule and thermoform it into or over a complementary shaped mould, in particular by at a same time using vacuum and / or pressure. This is particularly important because the main capsule bodies must be thermoformed with such high definition and reliability that the relative high pressures and temperatures that arise during brewing with such a capsule in a machine cannot lead to uncontrolled openings of the capsules at other locations than the foreseen outlet opening. In a preferred embodiment the outlet filtering openings can now be provided in lowermost parts of the lower fluid director member. This further helps to guarantee that all produced beverage now can efficiently flow through the lower fluid director member into the created outflow channels lying underneath it.

[0044] Further preferred embodiments of the invention are stated in the dependent subclaims.

[0045] The invention also relates to a method for manufacturing of the capsules according to claims 12-15.

[0046] DETAILED DESCRIPTION OF THE DRAWINGS

[0047] The invention shall now be explained in more detail below by means of describing some exemplary embodiments in a non-limiting way with reference to the accompanying drawings, in which:

[0048] - Fig. 1 shows a cross-sectional cut open perspective view of an embodiment of the capsule according to the present invention;

[0049] - Fig. 2 shows a perspective view from below of the main capsule body of fig. 1 ;

[0050] - Fig. 3a shows a perspective view from below of a first of the main capsule body of fig. 2;

[0051] - Fig. 3b shows a cross-sectional cut open partial perspective view of a lower portion of the main capsule body of fig. 3a with a lower fluid director member already positioned therein;

[0052] - Fig. 4a shows a perspective view from below of a second variant of the main capsule body of fig. 2;

[0053] - Fig. 4b shows a cross-sectional cut open partial perspective view of a lower portion of the main capsule body of fig. 4a with a lower fluid director member already positioned therein;

[0054] - Fig. 5a shows a top view of a third variant of the main capsule body of fig. 2;

[0055] - Fig. 5b shows a cross-sectional cut open partial perspective view of a lower portion of the main capsule body of fig. 5a;

[0056] - Fig. 6a-d schematically show four steps of a thermoforming method for manufacturing the capsule according to the present invention;

[0057] - Fig. 7a-c schematically show three steps of a second embodiment of the thermoforming method;

[0058] - Fig. 8a-b schematically show two steps of a third embodiment of the thermoforming method;

[0059] - Fig. 9a shows a cross-sectional view of another embodiment of the capsule body according to the present invention; - Fig. 9b shows an enlarged partial view of fig. 9a at the position of a raised portion in the base wall;

[0060] - Fig. 10a shows a cut open perspective view of the capsule body of fig. 9;

[0061] - Fig. 10b shows a top view of the capsule body of fig. 9, in which the relief pattern of convexly rounded raised portions is clearly visible;

[0062] - Fig. 10c shows a bottom view of the capsule body of fig. 9, in which the inverted relief pattern of hollows underneath the raised portions is clearly visible; and

[0063] - Fig. 11a and b show a male and female die for compression-thermoforming the inventive profiled relief in an initially flat base wall of a thermoformed cup-shaped capsule body in an open position and in a closed position.

[0064] In fig. 1 a single-serve coffee capsule is shown that has been given the reference C. This type of capsule is compatible with a so called Tchibo® I Cafissimo® capsule platform currently available in the market. It comprises four parts, that is to say a cup-shaped main capsule body (MCB), a lower fluid director member LF, an upper fluid director member UF, and a cover member CM.

[0065] The main capsule body MCB has been thermoformed out of sheet material. The sheet material preferably is made out of biodegradable and / or compostable (plastic) single-layer or multi-layer material(s). The main capsule body MCB at its bottom side has a profiled base wall BWthat integrally transits into a circumferential side wall SW. See also fig. 2. The main capsule body MCB has an open top end delimited by a thermoformed outwardly projecting flange F.

[0066] In a bottom portion of the main capsule body MCB at a level above the base wall BW, the side wall SW is thermoformed with a lower inwardly projecting side wall edge LE. In a top portion of the main capsule body MCB at a level underneath the flange F, the side wall SW is thermoformed with a lower inwardly projecting side wall edge LE.

[0067] The profiled base wall BW has been thermoformed out of the sheet material with a pattern of upwardly raised portions RP. Outer ones of the raised portions RP' are thermoformed as annular segments, inner ones of the raised portions RP" are thermoformed as cylindrical segments. The raised portions RP have been thermoformed with upright sides and with flat horizontal tops. Between the raised portions RP, the base wall BW has been thermoformed with flat bottoms. Transitional edges between the flat bottoms and the upright sides, as well as between the upright sides and the flat horizontal tops have been thermoformed convexly rounded respectively concavely rounded. Between the raised portions RP a spoke-wheel pattern of interconnected outflow channels OFC is defined, that is delimited downwards by the flat bottoms and sideways by the upright sides. At its center the base wall comprises a flat bottom that is referred to as lower piercing position LPP. This lower piercing position LPP is destined to be pierced by an upwardly movable outlet piercing member of a coffee machine, for example a spike, at a start of a brewing cycle. After having been pierced, a central outlet opening is made in the base wall BW, which outlet opening then connects to the pattern of interconnected outflow channels OFC.

[0068] The profiled base wall BW has been thermoformed with a slightly thicker wall thickness t2 than the wall thickness t1 with which the side wall SW has been thermoformed.

[0069] The lower fluid director member LF has been punched out of sheet material. The sheet material preferably is made out of biodegradable and / or compostable (plastic) singlelayer or multi-layer material(s). The lower fluid director member LF has a flat disc-shape and comprises a circumferential portion that is closed and a central portion that is provided with a large number of outflow openings OFO. The lower fluid director member LF has been heat welded on top of and against the lower inwardly projecting side wall edge LE of the main capsule body MCB.

[0070] The lower fluid director member LF is configured such strong that it is well able to withstand weight and pressure forces during brewing. The flat horizontal tops of the raised portions RP then may form support against which the lower fluid director member LF may come to rest.

[0071] The lower fluid director member LF preferably is configured such strong that it is not only able to function as a filter for the coffee during brewing but at a same time also is well able to form a protective blocking wall that lies spaced above the lower piercing position LPP and that shields the spike from accidentally getting penetrated through it.

[0072] A batch of coffee powder (not shown here) is provided inside the cup-shaped main capsule body MCB on top of the lower fluid director member LF. The amount of this batch and its composition may differ per type of coffee to be brewed. An upper surface of the batch of coffee powder lies below the level of the upper inwardly projecting side wall edge UE of the main capsule body MCB.

[0073] The outflow openings OFO in the lower fluid director member LF preferably have diameters that are less than a statistical mean diameter of particles in the coffee powder. Thus the lower fluid director member LF is well able to function as a filter that prevents coffee powder particles to end up underneath the lower fluid director member LF in the outflow channels OFC and thus possibly also via the pierced outlet opening in a brewed cup of coffee. The upper fluid director member UF has been punched out of sheet material. The sheet material preferably is made out of biodegradable and / or compostable (plastic) singlelayer or multi-layer material(s). The upper fluid director member UF has a flat disc-shape and comprises a circumferential portion that is closed and a central portion that is provided with a large number of inflow openings IFO. The upper fluid director member UF has been heat welded on top of and against the upper inwardly projecting side wall edge UE of the main capsule body MCB.

[0074] The cover member CM has been punched out of sheet material. The sheet material preferably is made out of biodegradable and / or compostable (plastic) single-layer or multilayer material(s). The cover member CM has a flat disc-shape and initially is closed over its entire surface. The cover member CM has been heat welded on top of and against the flange F of the main capsule body MCB.

[0075] A free space is delimited between the upper fluid director member UF and the cover member CM, which is referred to as injection space IS.

[0076] A center of the cover member is referred to as upper piercing position UPP. This upper piercing position UPP is destined to be pierced by a downwardly movable inlet piercing member of a coffee machine, for example a hollow injection needle, at a start of a brewing cycle. After having been pierced, the injection needle may start to inject pressurized hot water into the injection space IS. In this injection space IS the injected water shall quickly and neatly spread out over the entire upper fluid director member UF, and start flowing simultaneously through all the inlet filtering openings IFO. This helps to guarantee that the entire batch of coffee powder gets penetrated such that no dead unused zones may arise therein.

[0077] The upper fluid director member UF is configured such strong that it is well able to withstand pressure forces during brewing. The upper surface of the batch of coffee then may provide support against which the upper fluid director member UF may come to rest.

[0078] The upper fluid director member UF preferably is configured such strong that it is not only able to function as a distributor for the injected water but at a same time also is well able to form a protective blocking wall that lies spaced underneath the upper piercing position UPP and that shields the injection needle from accidentally getting penetrated through it.

[0079] The inflow openings IFO in the upper fluid director member LF preferably have diameters that are less than a statistical mean diameter of particles in the coffee powder. Thus the upper fluid director member LF is well able to function as a filter that prevents coffee powder particles to end up above the upper fluid director member during the pressurized injection of hot water in the injection space IS above it and thus possibly smoothening the injection needle.

[0080] In fig. 3 a first variant is shown wherein the base wall of the main capsule body has now been thermoformed with conical segments as raised portions RP. The raised portions RP have here been thermoformed with angled sides and with rounded tops. Between the raised portions RP, the base wall has been thermoformed with flat bottoms. The raised portions RP here are provided in a pattern of three circles that between them define a meandering pattern of interconnected outflow channels, that is delimited downwards by the flat bottoms and sideways by the angled sides.

[0081] At its center the base wall comprises a flat bottomed lower piercing position LPP that is destined to be pierced by an upwardly movable outlet piercing member of a coffee machine, for example a spike, at a start of a brewing cycle, and then form a central outlet opening in the base wall BW that connects to the pattern of interconnected outflow channels.

[0082] In fig. 4 a second variant is shown wherein the base wall of the main capsule body has now been thermoformed with squared segments as raised portions RP. The raised portions RP have here been thermoformed with angled sides and with flat tops. Between the raised portions RP, the base wall has been thermoformed with flat bottoms. The raised portions RP here are provided in a pattern of two circles that between them define a meandering pattern of interconnected outflow channels, that is delimited downwards by the flat bottoms and sideways by the angled sides.

[0083] At its center the base wall comprises a flat bottomed lower piercing position LPP that is destined to be pierced by an upwardly movable outlet piercing member of a coffee machine, for example a spike, at a start of a brewing cycle, and then form a central outlet opening in the base wall BW that connects to the pattern of interconnected outflow channels.

[0084] In fig. 5 a third variant is shown wherein the base wall of the main capsule body has now been thermoformed with merely annular segments as raised portions RP. The raised portions RP have here been thermoformed with upright sides and with flat tops. Between the raised portions RP, the base wall has been thermoformed with flat bottoms. The raised portions RP here are provided in a pattern of four circles that between them define a spokewheel pattern of interconnected outflow channels, that is delimited downwards by the flat bottoms and sideways by the upright sides.

[0085] At its center the base wall now comprises a visible lower piercing position LPP that is specifically configured to be pierced by an upwardly movable outlet piercing member of a coffee machine, for example a spike, at a start of a brewing cycle, and then form a central outlet opening in the base wall BW that connects to the pattern of interconnected outflow channels. The specifically configured lower piercing position for example can be thermoformed as a thinner weakened bottom wall portion such that the piercing is made easier. It can also be thermoformed as a small indent such that it may help to center the piercing element during its upward movement.

[0086] In fig. 6a-d a method for thermoforming the above described cup-shaped main capsule body MCB is schematically shown. For that a heating element HE is provided that is configured to heat and thus soften sheet material SM that is clamped underneath it. See fig. 6a. A thermoforming mould M here is shown underneath the heating element HE in a simplified straightforward manner. The thermoforming mould M delimits an inner cavity shape that fully corresponds to the shape of the main capsule body MCB to be thermoformed, that is to say including a plurality of raised and recessed portions on a bottom of the cavity (not shown) for co-manufacturing the base wall BW of the main capsule body MCB with its plurality of raised portions RP and outflow channels OFC therebetween. Furthermore, the mould M is provided with a number of small vacuum holes VH that connect to a underpressure / vacuum cq overpressure air source.

[0087] After the sheet material SM is sufficiently heated, it gets lowered to an upper side of the mould M. See fig. 6b. Due to the heating, the sheet material SM sags into the cavity.

[0088] Subsequently, an underpressure / vacuum, which is schematically indicated with an arrow V, gets applied in a space underneath the mould M, which via the vacuum holes VH also gets to act inside a space between the mould M and the sheet material SM. Due to this the sheet material SM gets drawn further into the cavity. See fig. 6c.

[0089] The underpressure / vacuum V is maintained until the sheet material SM has come to neatly lie against the entire inner wall of the mould M. See fig. 6d. After the sheet material SM has cooled off sufficiently for it to maintain its thermoformed shape, the underpressure / vacuum V gets taken away, such that the thus integrally thermoformed main- capsule body MCB including the raised portions RP and outflow channels OFC in its base wall BW can be removed from the mould M.

[0090] As can be seen in fig. 6d, the main capsule body MCB in this way can be thermoformed with a wall thickness of its side wall SW becoming smaller than a wall thickness of its base wall BW. This is advantageous because the thermoforming of the integrally formed raised portions RP requires extra material at that position.

[0091] Instead of immediately after it has been sufficiently heated, starting to pull the heated sheet material SM into the cavity, it is also possible to first place the space underneath the mould M at an overpressure P, which via the vacuum holes VH also gets to act inside the space between the mould M and the sheet material SM. Due to this the sheet material SM gets to billow upwards, until it runs against a plug PL. See fig. 7a. Depending on where the plug PL is given its upper starting position, this shall lead to the sheet material SM getting pre-stretched to a certain extent.

[0092] Subsequently, the overpressure P can be replaced for underpressure / vacuum V, while the plug PL can be displaced to push the sheet material SM downwards.

[0093] As can be seen in fig. 7c the thus included pre-stretching step leads to another ratio between the wall thickness of the side wall SW relative to the wall thickness of the base wall BW. Depending on the foreseen pattern of integrally thermoformed raised portions RP, this including of the additional pre-stretching step makes it advantageously possible to thermoform the main capsule body MCB according to the invention without local weak spots whatsoever.

[0094] Instead of or in addition to pulling the sheet material SM into the cavity under underpressure / vacuum V, it is also possible to place a space above the sheet material SM at an overpressure P. See fig. 8a. Due to this air pressure P from above, the sheet material SM gets pushed over its entire top surface into the cavity.

[0095] Thus the sheet material SM can get strongly pushed into all kinds of recessed cavity shapes RCS for example ones that correspond to the plurality of outflow channels OFC between the plurality of raised portions RP of the thermoformed base wall BW. See fig. 8b. This may help to make the shapes of the integrally thermoformed outflow channels OFC and raised portions RP more detailed and precise.

[0096] In fig. 9 and 10 a fourth variant is shown wherein the base wall of the main capsule body has now been thermoformed with a plurality of hollow dome-shaped raised portions RP. Each hollow dome-shaped raised portion has substantially parallel lower and upper sides. Bottom portions of the base wall that lie between the respective raised portions are substantially flat and define a plurality of outflow channels OFC therebetween for directing produced beverage flow towards a central lower piercing position LPP.

[0097] The shown capsule body has been thermoformed out of sheet material with an initial wall thickness to of between 0,5-0, 6 mm. An outwardly projecting flange that circumvents an open top end of the main capsule body and against which a cover member is to be attached, may well have remained substantially equal to the initial wall thickness to. The circumferential side wall and base wall of the capsule body may well have gotten wall thicknesses t1 and t2 that are thinner, for example up to 30 or 40% thinner, after the thermoforming has been completed than the initial wall thickness to of the original sheet material before the thermoforming. Fig. 9b shows an enlarged view of such a raised portion RP. There it is also indicated that the hollow dome-shaped lower side of the raised portion has a height hi of between 0,5- 1 ,5 mm, in particular between 0,7-1, 2 mm. Furthermore, it can be seen there that each raised portion RP has here been thermoformed with angled sides together enclosing an angle a of between 75-85°, in particular 80°. The transitional circumferential edge between the angled sides and the flat base wall portions have been thermoformed convexly rounded respectively concavely rounded with a curvature of radius r1 of between 0,4-0.6 mm, in particular about 0,5 mm. The rounded top of the dome-shaped lower side of the raised portion RP has an inner curvature radius r2 of between 0, 7-1,1 mm, in particular about 0,9 mm. The rounded top of the dome-shaped upper side of the raised portion RP has an outer curvature radius r3 of between 1 ,1-1, 5 mm, in particular about 1 ,3 mm. The raised portion RP has a maximum width w1 at the level of the transitional circumferential edge between the angled sides and the flat base wall portions of between 2-3 mm, in particular about 2,4 mm.

[0098] The wall thickness t2 of the raised portion RP lies between 0,3-0, 5 mm, in particular about 0,4 mm. The wall thicknesses t2' and t2" of the flat base wall portions at the locations of the outflow channels OFC and central lower piercing position LPP are substantially the same as the wall thickness t2 of the raised portion RP, and also lie between 0,3-0, 5 mm, in particular about 0,4 mm.

[0099] The capsule body of fig. 9 and 10 has been thermoformed in two steps. In the first step a basic cup-shape with a flat base wall and a circumferential side wall has been thermoformed (not shown). Subsequently, in the second step this basic cup-shape with its flat base wall gets positioned in between a male die MD and a female die FD. The male die MD and the female die FD have complementary reliefs Rup and Rio of the plurality of raised portions RP. See fig. 11a.

[0100] The male die MD and the female die FD can be pre-heated, and the thermoformed basic cup-shape can be placed between them (not shown). Subsequently, the male die MD and the female die FD can be moved towards each other (fig. 11b) such that the relief of the plurality of raised portions RP gets compression-thermoformed / heat-stamped into the initially flat base wall. By splitting up the thermoforming process in two distinctive steps it has appeared that the relief of raised portions RP can more accurately and reliably be thermoformed into the capsule body's base wall with substantially uniform wall thickness, such that no weak spots arise.

[0101] Besides the shown and described embodiments, numerous variants are possible. For example the dimensions and shapes of the various parts can be altered. Also it is possible to make combinations between advantageous aspects of the shown embodiments. All kinds of materials can be used for the components of the capsule. Preferably however they are made of one same material, like for example a biodegradable and / or compostable plastic.

[0102] If desired a distinctive filter element, for example one being made of paper material, can be placed on top of the lower fluid director member. This makes it possible to make the lower fluid director with relative large outlet filtering openings, and have the additional filter element comprise micro-perforations

[0103] Instead of using an entirely flat disc-shaped lower fluid director member, it is also possible to have it comprise an upwardly directed, for example conically shaped, recess and / or some kind of bowl shape. The lower fluid director member then may serve both as a collecting means and as a filter for the prepared beverage. At a same time the recess then may advantageously provide some additional height to further help preventing that the outlet piercing member may accidentally pierce through the lower fluid director member and then may come in direct contact with the substance. In that case, the lower fluid director member advantageously also can be thermoformed out of same sheet material as the main capsule body.

[0104] Instead of using an entirely flat disc-shaped upper fluid director member, it is also possible to have it comprise a downwardly directed, for example conically shaped, recess and / or some kind of inverted bowl shape. The upper fluid director member then may serve both as a distributing means and as a filter. At a same time the recess then may advantageously provide some additional depth to further help preventing that the inlet piercing member may accidentally pierce through the upper fluid director member and then may come in direct contact with the substance. In that case, the upper fluid director member advantageously also can be thermoformed out of same sheet material as the main capsule body.

[0105] It should be understood that various changes and modifications to the presently preferred embodiments can be made without departing from the scope of the invention, and therefore will be apparent to those skilled in the art. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims

CLAIMS1. A capsule (C) for containing a substance from which a beverage can be produced, comprising:- a cup-shaped main capsule body (MCB) that has: o a base wall (BW) configured to be pierced at a lower piercing position (LPP) by an outlet piercing member for forming an outlet opening; and o a circumferential side wall (SW), wherein the side wall (SW) and the base wall (BW) define a space with an open top end for containing said substance,- a cover member (CM) attached to and covering the open top end of the main capsule body (MCB) and configured to be pierced at an upper piercing position (UPP) by an inlet piercing member for injection of a pressurized fluid; and- a lower fluid director member (LF) disposed within a bottom portion of the main capsule body (MCB) between the substance and the base wall (BW), wherein the lower fluid director member (LF) is dimensioned to correspond to an interior cross-sectional area of the bottom portion of the main capsule body (MCB), wherein the lower fluid director member (LF) defines a plurality of outlet filtering openings (OFO) for passage of produced beverage therethrough, and wherein a plurality of raised portions (RP) are provided that define a plurality of outflow channels (OFC) therebetween arranged to direct produced beverage flow from the plurality of outlet filtering openings (OFO) towards said lower piercing position (LPP), characterized in that, the plurality of raised portions (RP) have been integrally formed by means of thermoforming in the base wall (BW) of the main capsule body (MCB), wherein the lower fluid director member (LF) that defines the plurality of outlet filtering openings (OFO) for the passage of the produced beverage therethrough, is positioned above the integrally formed raised portions (RP) of the base wall (BW) of the main capsule body (MCB).

2. Capsule according to claim 1, wherein the main capsule body (MCB) including the base wall (BW) with its integral co-manufactured plurality of raised portions (RP) that define the plurality of outflow channels (OFC) therebetween, has been manufactured by means of thermoforming out of sheet material (SM), resulting in wall thicknesses of the thermoformed side and base walls that are thinner than the wall thickness of the sheet material.

3. Capsule according to one of the preceding claims, further comprising:- an upper fluid director member (UF) disposed within a top portion of the main capsule body (MCB) between the substance and the cover member (CM), wherein the upper fluid director member (UF) is dimensioned to correspond to an interior cross-sectional area of the top portion of the main capsule body (MCB), wherein the upper fluid director member (UF) defines a plurality of inlet filtering openings (IFO) for passage of injected pressurized fluid therethrough, and wherein the upper fluid director member (UF) is positioned in the top portion underneath the cover member (CM) to define an injection space (IS) to distribute injected fluid during beverage production towards the plurality of inlet filtering openings (IFO).

4. Capsule according to one of the preceding claims, wherein the lower and / or upper fluid director member (LF, UF) has / have been manufactured out of a same type of base material as the main capsule body (MCB).

5. Capsule according to one of the preceding claims, wherein the lower and / or upper fluid director member (LF, UF) has / have a flat disc-shape that has / have been manufactured out of sheet material (SM).

6. Capsule according to one of the preceding claims, wherein the lower and / or upper fluid director member (LF, UF) has / have been welded or glued with an outer circumferential bottom surface portion against lower and / or upper inwardly projecting side wall edge(s) (LE, UE) of the main capsule body (MCB).

7. Capsule according to one of the preceding claims, wherein the lower and / or upper fluid director member (LF, UF) is / are configured to form a protective blocking wall above and / or underneath the lower and / or upper piercing position(s) (LPP, UPP).

8. Capsule according to one of the preceding claims 1-7, wherein the raised portions (RP) of the base wall (BW) of the main capsule body (MCB) have been integrally formed by means of thermoforming with flat tops.

9. Capsule according to one of the preceding claims 1-7, wherein the raised portions (RP) of the base wall (BW) of the main capsule body (MCB) have been integrally formed by means of thermoforming with rounded tops.

10. Capsule according to one of the preceding claims, wherein a wall thickness (t1) of the side wall (SW) is smaller than a wall thickness (t2) of the base wall (BW) with its integrally formed raised portions (RP).

11. Capsule according to one of the preceding claims, wherein the outlet filtering openings (OFO) are provided in lowermost parts of the lower fluid director member (LF).

12. A method of manufacturing the capsule according to one of the preceding claims, comprising a step of:- integrally forming by means of thermoforming the plurality of raised portions (RP) in the base wall (BW) of the main capsule body (MCB);- positioning the lower fluid director member (LF) that defines the plurality of outlet filtering openings (OFO) above the integrally formed raised portions (RP) of the base wall (BW) of the main capsule body (MCB);- filling a space above the lower fluid director member (LF) with substance from which a beverage can be produced;- attaching the cover member (CM) to the open top end of the main capsule body (MCB).

13. Method according to claim 12, wherein the main capsule body (MCB) including the base wall (BW) with its integrally co-manufactured plurality of raised portions (RP) that define the plurality of outflow channels (OFC) therebetween, is manufactured by means of thermoforming sheet material (SM) into or over a mould (M).

14. Method according to claim 13, wherein the main capsule body (MCB) is thermoformed with a wall thickness (t1) of the side wall (SW) becoming smaller than a wall thickness (t2) of the base wall (BW) with its integrally formed raised portions (RP).

15. Method according to claim 13 or 14, wherein the lower and / or upper fluid director member (LF, UF) are punched out of sheet material (SM) of a same type as the sheet material (SM) out of which the main capsule body (MCB) is thermoformed.

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