Method for obtaining an exit opening of a capsule

Abstract

The present invention relates to a method for obtaining at least outlet openings 8 in a carrier disk 7 that can be provided in an interior space of a capsule 1 for preparing a beverage, the outlet openings being suitable for discharging a prepared beverage from the interior space towards the outside of the capsule when the capsule is used in a beverage preparation device. The method includes providing a sheet material 70 from which a carrier disk having outlet openings can be obtained, cutting the sheet material by means of a cutting device to obtain a first set of outlet openings, aligning the first set of outlet openings relative to the cutting device by means of alignment elements 101 extending through alignment openings 71 provided in the sheet material, cutting the sheet material with the aligned first set of outlet openings by means of the cutting device to obtain a second set of outlet openings, and intermittently moving the sheet material at different distances relative to the cutting device.

Description

[Technical Field]

[0001] The present invention relates to a method for obtaining at least an outlet opening for a carrier disc of a capsule with an integrated filter element for preparing a beverage, preferably a coffee-, tea-, milk- or chocolate-based beverage without crema. [Background technology]

[0002] Capsules for preparing a beverage in a beverage preparation device, which exhibit the above characteristics, are generally known from the prior art. The beverage preparation device comprises a brewing chamber in which the capsule is placed. Liquid from the beverage preparation device is injected into the capsule to extract a beverage from extractable ingredients, typically roast and ground coffee or tea, or to prepare a beverage from soluble ingredients contained within the capsule's internal space, typically instant coffee, instant tea or instant milk, or a chocolate-based product.

[0003] In many of the capsules currently on the market, the interior space of the capsule is closed, sealed or liquid-tightly sealed from the environment prior to use in a beverage preparation device in order to maintain or prolong the freshness of the beverage ingredients during storage.

[0004] In this regard, a capsule often comprises a substantially rigid capsule body having a circumferential sidewall extending around an interior space and a base wall covering the interior space at a first end of the sidewall. The capsule body has an open filling surface at a second end of the sidewall opposite the base wall. A fluid- and gas-tight lid, e.g., an aluminum lid, is provided over the open filling surface of the capsule body to cover the interior space. In use, the capsule may be preferably perforated in the base wall and / or the lid to form an inlet opening for injecting a liquid, such as hot water, and / or an outlet opening to allow the prepared beverage to exit the capsule.

[0005] The known capsules are more particularly designed for preparing espresso-type beverages using a beverage preparation device that delivers high-pressure hot water, the injection of the pressurized hot water into the capsule resulting in the extraction of substances from the coffee beverage ingredients and the formation of a foam on the beverage that corresponds to an espresso beverage with a crema layer as obtained in known piston-type espresso machines that use high-pressure brewing.

[0006] For coffee drinks without crema, for example coffee drinks without foam, also called filter coffee, specific devices are usually used in which the drink is prepared by non-pressurized filtration of a mixture of the beverage ingredients and water.

[0007] For the preparation of coffee without crema, several capsules have been proposed for use in pressurized beverage devices.

[0008] EP 2952125 A1 discloses a capsule for preparing a beverage using an extractable product contained within the capsule's internal space. The capsule comprises a first circumferential wall, a second wall closing the first circumferential wall at a first end, and a flexible, sheet-like, perforated and / or porous third wall closing the first circumferential wall at a second open end opposite the second wall, thereby forming the internal space. The third wall forms the capsule's outermost boundary in the axial direction and comprises a woven or nonwoven 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 that bound an interior space filled with beverage ingredients. An open filling surface of the capsule at the end of the circumferential wall opposite the base wall is covered with a lid made of a liquid-tight material. The lid has a preformed outlet opening suitable for discharging the prepared beverage from the interior space when the capsule is used in a beverage preparation device. The outlet opening is closed in a liquid-tight manner by a removable cover element that extends over at least a portion of the lid.

[0010] However, these solutions are not entirely satisfactory with regard to the structure of the capsule, its ergonomic use by the consumer, and the result obtained in the cup. Furthermore, there is a need to manufacture the capsule parts cost-effectively and accurately, specifically so that the result obtained in the cup has a high quality.

[0011] The object of the proposed invention is therefore to provide a method for cost-effectively and accurately obtaining at least some capsules suitable for producing a crema-free filter-type coffee drink having all the characteristics of filter coffee made in a drip coffee machine and matching the sensory result expected by the consumer to be obtained in the cup. Summary of the Invention

[0012] In this respect, the present invention provides a method for obtaining at least an outlet opening for a carrier disc that can be provided in an interior space of a capsule for preparing a beverage, the outlet opening being suitable for discharging a prepared beverage from the interior space towards the outside of the capsule when the capsule is used in a beverage preparation device, the method comprising: providing a sheet material from which a carrier disc having an outlet opening can be obtained; cutting the sheet material with a cutting device to obtain a first set of exit openings; aligning the first set of outlet openings with respect to the cutting device by alignment elements extending through alignment openings (such as guide holes, centering holes, positioning holes, or datum holes) in the sheet material; and cutting the sheet material having the first set of exit openings so aligned with a cutting device to obtain a second set of exit openings.

[0013] Specifically, "alignment" can include guiding, centering, and / or positioning relative to the cutting device. By virtue of alignment elements extending through the alignment openings, at least a first set of outlet openings can be automatically centered relative to the cutting device. Thus, the alignment openings can be used to "auto-center" the hole cuts in the cutting device.

[0014] Thus, the first set of outlet openings and the second set of outlet openings, which together form at least a portion of the outlet openings of the carrier disk obtained from the sheet material, can be manufactured very accurately, i.e., with high precision. This is because the step of aligning the first set of outlet openings with 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. The second set can thereby be provided accurately relative to the first set, specifically, so that the outlet openings of the set consisting of the first set of outlet openings and the second set of outlet openings are evenly (i.e., uniformly) distributed. Specifically, at least the first and second sets of outlet openings can be obtained such that the sets are adjacent to or overlap each other. By "multiple sets of outlet openings overlap each other," we mean that at least some of the outlet openings of one set are disposed between at least some of the outlet openings of each of the other sets, and each outlet opening included in the overlap thus formed is not integrated with another outlet opening.

[0015] Specifically, the resulting outlet openings, including at least the first and second sets of outlet openings, can be positioned very close to one another, thereby making it possible to obtain a carrier disk with a particularly large number of outlet openings that are precisely positioned relative to one another. Furthermore, the precisely positioned outlet openings thus obtained do not require complex manufacturing equipment, since the method particularly makes it possible to avoid the need to obtain a large number of outlet openings positioned very close to one another in a single cutting step. Rather, a large number of outlet openings positioned even more precisely relative to one another can be obtained in at least two cutting steps, or in other words, split into or distributed over several cutting steps, for example, using a reduced number of cutting stations. This, in particular, can reduce the cutting pressure and the space required for the cutting device, especially since the cutting device does not need to process a large number of outlet openings at one time. Instead, the cutting device can be adjusted to process only a portion of the total number of outlet openings of the carrier disk, thereby saving space. In other words, at least some of the exit openings in the carrier disk may be provided by cutting a first set of exit openings with a cutting device, advancing or moving the sheet material relative to the cutting device to align the first set of exit openings, and then cutting a second set of exit openings having the same hole pattern with the cutting device.

[0016] Furthermore, obtaining the exit opening of the carrier disc in at least two cutting steps offers the advantage that only a small amount of small particles are separated as waste during the entire cutting process, thus improving material efficiency.

[0017] The resulting outlet openings, positioned in a highly precise manner (e.g., within a tolerance of less than 0.1 mm) and preferably numerous, can be advantageously used in the carrier disc of a capsule for preparing a beverage. For example, if the capsule contains roasted and ground coffee as a beverage ingredient, the specific structure of the defined carrier disc, particularly the outlet opening, allows for coffee with limited foam and crema formation to be obtained when the capsule is brewed after the lid is removed. This brewed coffee may have the main characteristics of filter-like coffee: low crema and quickly disappearing (in less than one or two minutes), leaving only a crown of crema around the cup. The resulting cup is a coffee with a fragrant, soft, smooth, sweet taste, yet light-bodied, low acidity, low bitterness, and a mild, non-irritating flavor. Specifically, when the outlet opening is defined by a carrier disc disposed within the capsule's interior space, it can be obtained in such a way that water channeling, which may occur within the coffee bed (in the capsule) during brewing, is avoided.

[0018] In the context of the present invention, "cutting" should be understood to encompass different cutting techniques or methods. For example, cutting can include or be punching. Additionally or alternatively, cutting can include or be cutting by using heat (e.g., by using a laser) and / or by using chip formation (e.g., drilling) and / or by using other methods involving shearing.

[0019] The method may include detecting an alignment opening, and upon detection, performing an alignment step of moving an alignment element to extend through the alignment opening so detected. The detection may be performed by an optical device.

[0020] The method may further include aligning the multiple sets of outlet openings relative to the cutting device using alignment elements extending through additional (e.g., second) alignment openings (such as guide holes, centering holes, or positioning holes) provided in the sheet material, and cutting the sheet material having the multiple sets of outlet openings thus aligned with the cutting device to obtain a further set, e.g., a third set, of outlet openings. Thus, the same alignment elements can be used to align the first set of outlet openings relative to the cutting device and, in the further alignment step, to align at least the first and second sets of outlet openings relative to the cutting device, so that, in the subsequent cutting step, the third set of outlet openings is obtained, for example, adjacent to the second set of outlet openings. Thus, obtaining a large number of outlet openings with high precision is even more simplified. For example, the further (or third) set of outlet openings may have the same hole pattern as each of the first and second sets.

[0021] The method may further include aligning the multiple sets of outlet openings (e.g., the first to third sets) with respect to the cutting device by means of additional (e.g., second) alignment elements extending through alignment openings in the sheet material, and cutting the sheet material having the aligned multiple sets of outlet openings with the cutting device to obtain additional (or even further, e.g., fourth) sets of outlet openings. The additional alignment elements may align the multiple sets of outlet openings with a portion of the cutting device that is different from the portion of the cutting device with which the (first) alignment element aligns at least the first set of outlet openings. This makes it particularly possible for the additional set of outlet openings to have a different hole pattern from the hole pattern of each of the first and / or second sets of outlet openings and / or the third set, if present. Thus, outlet openings can be obtained in a highly advantageous manner, for example, by including overlapping sets of outlet openings each having a different hole pattern.

[0022] The method may further include aligning the multiple sets of outlet openings (e.g., the first through fourth sets) with a cutting device using additional alignment elements extending through additional alignment openings in the sheet material, and cutting the sheet material having the aligned multiple sets of outlet openings with the cutting device to obtain a still further (or even further, e.g., a fifth) set of outlet openings. For example, the same alignment elements can be used to align the first through third sets of outlet openings and to align the first through fourth sets of outlet openings in the additional alignment step, so that in the subsequent cutting step, a fifth set of outlet openings is obtained, for example, adjacent to the fourth set of outlet openings but overlapping one or more of the first through third sets of outlet openings. For example, the still further (or fifth) set of outlet openings has a hole pattern identical to the hole pattern of the fourth set.

[0023] The method may further include aligning the multiple sets of outlet openings (e.g., sets 1 to 5) with a cutting device by means of additional alignment elements extending through additional (or even further, e.g., third) alignment openings provided in the sheet material, and cutting the sheet material having the multiple sets of outlet openings so aligned with the cutting device to obtain an additional (e.g., sixth) set of outlet openings, for example, the sixth set of outlet openings having a hole pattern identical to the hole pattern of each of the fourth and fifth sets.

[0024] At least some of the outlet openings of one set of outlet openings may be disposed between the outlet openings of each of the other sets of outlet openings. In other words, one set may overlap each of the other sets. For example, the other sets may be provided such that at least some of the openings are surrounded by a section of sheet material, and at least one outlet opening of one set is cut in this section of sheet material, so that this outlet opening is disposed between the outlet openings of the other set. This allows a particularly large number of outlet openings to be disposed close to one another in a precise manner.

[0025] The method may further include a step of cutting the sheet material with a cutting device to obtain alignment openings. Specifically, the alignment openings may be obtained in the step for obtaining the first set of outlet openings. For example, the cutting step of cutting the sheet material to obtain the first set of outlet openings may result in a hole pattern including the alignment openings. The cutting device may have a first cutter for obtaining the first set of outlet openings and a second cutter for obtaining the alignment openings, and these cutters are at a fixed distance from each other during cutting. Further alignment openings may be obtained in the cutting step for obtaining the second set of outlet openings. Additional alignment openings may be obtained in the cutting step for obtaining the additional set of outlet openings. The further alignment openings and / or additional alignment openings may be obtained by the same cutter that obtains the alignment openings.

[0026] In other words, the first, second (or further), third (or additional) registration openings may be formed together 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 a cutting device to obtain the registration openings, for example registration openings obtained in the cutting step to obtain the first set of outlet openings, further registration openings obtained in the cutting step to obtain the second set of outlet openings, and additional registration openings obtained in the cutting step to obtain the third (or further) set of outlet openings.

[0027] The alignment openings, and optionally the further alignment openings, and if present, the additional alignment openings, may have a diameter larger than the diameter of each of the exit openings. The alignment elements may be pins such as pilot pins. The alignment openings may have a diameter larger than each of the exit openings but equal to or (slightly) smaller than the diameter of the alignment openings. The alignment elements may be adjusted to extend through one or more alignment openings to align one or more sets of exit openings with respect to the cutting device. During the alignment step, the feeder supplying the sheet material may allow movement of the sheet material with respect to the cutting device (i.e., the feeder releases the sheet material, e.g., the feeder does not apply tension to the sheet material), so that by moving the alignment elements through the alignment openings, the sheet material with at least a first set of exit openings can be accurately positioned with respect to the cutting device. The feeder can then prevent at least a portion of the sheet material with at least a first set of exit openings from moving with respect to the cutting device (e.g., by applying tension to at least a portion of the sheet material), so that the sheet material can be cut in an easy manner.

[0028] The method further includes intermittently moving the sheet material relative to the cutting device at different distances (or stroke advances or step lengths). The different distances may include 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 move during a first stage and stop during a second stage, during which at least the steps of aligning one or more sets of exit openings and cutting a further set of exit openings are performed. In other words, the sheet material may move relative to the cutting device by irregular stroke advances, such as three times by a stroke advance of distance A and four times by a stroke advance of distance B, where B is different from (e.g., greater than) A. During the movement of the sheet material (i.e., as the sheet material advances), the alignment element may be in a first position (e.g., a retracted position or an upper position) in which the alignment element is spaced apart from the sheet material. When the sheet material is stopped, the alignment elements may be in a second position (such as a protruding position, or a lowered position in which the alignment elements are moved downwards from an upper position) in which the alignment elements extend through the alignment openings to align at least the first set of exit openings. By intermittently moving the sheet material at different distances relative to the cutting device, complex patterns of exit openings in a (single) carrier disc (such as multiple interleaved sets of exit openings forming the exit openings of a carrier disc) can be obtained in a very easy way.

[0029] The method may further include moving the sheet material relative to the cutting device along a distance (e.g., a stroke) from a first position, where a first set of exit openings is obtained, to a second position, where a second set of exit openings is obtained. The cutting device may be stationary while the sheet material moves. Alternatively, the sheet material may be stationary while the cutting device moves. The same hole pattern (e.g., by using the same cutting station) or different hole patterns (e.g., by using different cutting stations) may be obtained at both positions.

[0030] The method may further include moving the sheet material relative to the cutting device along a further (second) distance from the second position to a third position, where a further (e.g., third set) or additional (e.g., fourth set) set of exit openings is obtained, the further distance being equal to or greater than the distance. For example, the further distance is equal to the distance at which the same hole pattern is obtained at all three positions. The further distance may be greater than the distance at which a different hole pattern is obtained at the third position than at the second position. For example, the greater distance may be used to move the sheet material relative to a different cutting station, such as a different punch.

[0031] The method may further include cutting the sheet material with a cutting device to obtain a carrier disk, such that the carrier disk comprises a plurality of sets of exit openings. The step of cutting the sheet material to obtain a carrier disk may be performed in a production line different from the production line in which the at least first and second sets of exit openings are obtained. In other words, the cutting device may include a first part (such as one or more first cutting stations) for obtaining the at least first and second sets of exit openings and a second part (such as one or more second cutting stations) for obtaining the carrier disk, and the second part may be located at a different location from the first part.

[0032] The method may further include aligning the multiple sets of outlet openings with respect to a 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, e.g., through a further or additional alignment opening; and cutting the sheet material with the cutting device (or with a cutting station different from and / or spaced apart from one or more cutting stations for obtaining at least the first and second sets) to obtain a carrier disk, such that the carrier disk comprises the multiple sets of outlet openings thus aligned. This allows the outlet openings to be provided in the carrier disk very precisely, specifically at a specified distance from the periphery of the carrier disk, or at least positioned within a circumferential cut line. Specifically, the cutting device is prevented from cutting the outlet openings provided in the sheet material. Specifically, the carrier disk may be obtained so that there are no outlet openings on its periphery over a distance of at least 1 mm, preferably 0.5 to 2.5 mm, more preferably 1 to 2 mm. This may enable safe and easy assembly within a capsule.

[0033] Obtaining outlet openings for the carrier disc may be a first manufacturing step, and obtaining a carrier disc with these outlet openings may be a second manufacturing step. The first and second manufacturing steps may be performed in different manufacturing lines. For example, the manufacturing lines are independent of each other (specifically, can operate independently of each other) and / or separate from each other. The first manufacturing step may be performed at the premises of a first supplier, and the second manufacturing step may be performed at the premises of a second supplier. Between the manufacturing steps, a sheet material with outlet openings may be transported (e.g., as a sheet roll). Obtaining the carrier disc or the second manufacturing step may be part of a filling device or machine or a filling line. In the filling device or machine or the filling line, the capsule body may be filled with beverage ingredients, and after this filling step, the sheet material may be cut to obtain a carrier disc (e.g., together with a filter element). After obtaining the carrier disc, the carrier disc (and, for example, simultaneously the filter element) may be transferred onto or into a capsule.

[0034] Specifically, the carrier disc may be obtained (eg, punched) with aligned hole patterns defined by at least two sets of exit openings.

[0035] The cutting device may be a punching device, and preferably the cutting of at least the first and second sets of outlet openings is performed by the same punch or by different punches, respectively. The punching device may comprise one or more dies arranged opposite the same punch or different punches. The punching device allows for multiple sets of outlet openings to be obtained by moving the punch back and forth, such as by moving it up and down.

[0036] The method may further comprise the step of providing a carrier disc within the interior space of the capsule for preparing the beverage.

[0037] The method may further include providing a filter element, which may comprise a layer of nonwoven material adapted to prevent coffee drainage and reduce the formation of a crema layer.

[0038] The method may be carried out on a multi-lane production line or machine.

[0039] The method may include a filling step, such as filling the capsule body with beverage ingredients. After filling with the beverage ingredients, a carrier disk having at least two sets of outlet openings may be provided on the capsule body. In other words, the method may be used in a multi-lane filling machine or line. 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, and even more preferably twelve or more filling stations, for example, twenty-four or more filling stations.

[0040] The method may further include positioning the filter element on a carrier disk, which allows for easy handling during the capsule assembly process. In addition, the method may include fixing the filter element (e.g., disposed on the carrier disk) on the carrier disk.

[0041] 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 0.5mm to 3mm, more preferably 1mm to 3mm. In particular, the outlet openings of one set of outlet openings that are located between outlet openings of another set of outlet openings may be spaced apart from these outlet openings by a distance of 0.5mm to 3mm, more preferably 1mm to 3mm.

[0042] Adjacent outlet openings of the same set of outlet openings may be spaced apart by a distance that is greater than the distance between adjacent outlet openings of a different set of outlet openings.

[0043] The plurality of sets of outlet openings or the plurality of outlet openings of the carrier disc, in particular the plurality of sets of outlet openings formed by the carrier disc, may comprise 50 to 150 outlet openings, preferably 70 to 120 outlet openings, more preferably 85 to 110. Such a structure with a plurality of openings is particularly advantageous for avoiding possible channeling of water within the coffee bed during extraction.

[0044] The plurality of sets of outlet openings or the plurality of outlet openings of the carrier disc, in particular the plurality of sets of outlet openings formed by the carrier disc, may be 1 mm 2 0.07 to 0.21 outlet openings per mm, preferably 1 mm 2 0.10 to 0.17 outlet openings per mm, more preferably 1 mm 2 Each of the nozzles may contain 0.12 to 0.16 outlet openings.

[0045] The open surface ratio of the carrier disc can be between 4% and 15%, preferably between 5% and 12%. The set open surface ratio allows no or reduced pressure build-up to occur in the capsule during extraction.

[0046] The exit opening may be a calibrated circular or oval opening. Such an exit opening shape is optimized for ease of manufacturing and lower tooling costs. However, other exit opening shapes may be selected depending on the cup results obtained.

[0047] The outlet opening may have a diameter of 0.4 mm to 3 mm, preferably 0.5 mm to 2 mm, more preferably 0.5 mm to 1.3 mm, these dimensions being calculated for a leak rate of about 300 mL / min.

[0048] The outlet openings may be uniformly distributed over the surface of the carrier disk, which helps to avoid channeling effects.

[0049] Each outlet opening of the carrier disc may be spaced from an adjacent outlet opening by a distance of 0.5mm to 3mm, more preferably 1mm to 3mm.

[0050] The carrier disc may have a generally circular shape with a diameter of 28.5 mm to 30.5 mm. Alternatively, the carrier disc may have another shape, such as an oval, polygonal or rectangular shape.

[0051] The thickness of the sheet material or carrier disc may be comprised 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, so that the carrier disc is sufficiently rigid to withstand ejection due to the pressure of the expanded coffee bed during or after extraction. In one embodiment, the thickness of the sheet material is about 0.3 mm (300 μm).

[0052] The sheet material may be made of aluminium, which allows for easy recycling in conventional aluminium streams, especially if the remaining capsules are also made of aluminium. Additionally or alternatively, the carrier disc may be made of plastic or laminated plastic elements.

[0053] The sheet material may be provided as or from a sheet roll, which may have a width (e.g., length of the sheet material transverse to the direction of travel of the sheet material) at least twice the diameter of the carrier disk from which the sheet material is derived, and may be in the form of a foil.

[0054] According to a further aspect, the present invention provides a capsule for preparing a beverage, the capsule comprising: a substantially rigid capsule body having a circumferential sidewall extending around an interior space of the capsule, the interior space being at least partially filled with a beverage ingredient suitable for preparing a beverage; a rigid base wall integral with the capsule body, the rigid base wall covering the interior space at the first end of the side wall; a flange circumferentially disposed around the open face of the capsule at a second end of the side wall of the base body opposite the base wall; a lid covering the interior space and the open face of the capsule at a second end of the side wall opposite the base wall and sealing the capsule, the lid being removably attached to the flange for use of the capsule in a beverage preparation device; a filter element disposed within the interior space of the capsule between the beverage ingredients and the lid; a carrier disc provided with an outlet opening obtained by the method as described above, the carrier disc being arranged in the interior space of the capsule, The carrier disc is disposed within the interior space of the capsule between the lid and the filter; The carrier disc has 50 to 150 outlet openings, and the open surface ratio of the carrier disc is higher than 4%.

[0055] Considering that the capsules undergo extraction in a beverage preparation device comprising an extraction plate with a tearing surface, the outlet openings may be uniformly distributed over the carrier disc, with less than 10% of the outlet openings of the carrier disc directly facing the tearing surface of the extraction plate. This feature allows the extracted coffee to exit the carrier disc unhindered and unaffected by the tearing surface near the extraction plate.

[0056] Furthermore, the pattern of distribution of the outlet openings across the carrier disc may be configured such that the distribution of the outlet openings is independent of the angular positioning of the carrier disc relative to the tearing surface of the extraction plate.

[0057] The capsule lid may be provided with a free pull tab that protrudes from the lid, which may be integral with the lid, allowing the entire lid to be removed, making handling and opening easier.

[0058] In one embodiment, the lid comprises at least an aluminium layer to ensure better shelf life of the coffee in the capsule.

[0059] Additionally, the lid may further comprise a plastic layer and / or a heat seal layer to ensure food grade compatibility for sealing the lid onto the flange of the capsule.

[0060] Preferably, the capsule body, lid and carrier disc are each made primarily from aluminium. The use of aluminium ensures better coffee protection and a longer shelf life. Furthermore, the capsules are easier to dispose of and easier to recycle.

[0061] Alternatively, the capsule body, lid and carrier disc may each be made of plastic or laminated or multi-layered plastic elements.

[0062] The beverage ingredient is preferably ground coffee in an amount of at least 4g, preferably between 4.5g and 15g.

[0063] Thanks to the proposed capsule structure, the carrier disc can be positioned inside the capsule and kept at a distance from the lid, for example 0.1 mm to 2 mm from the lid, which makes it possible to avoid possible interactions between the carrier disc and the tear surface of the brewing plate of the beverage preparation device when the coffee bed volume expands during brewing.

[0064] The capsule may be designed to sustain extraction of the beverage ingredients in an extraction process carried out at a pressure of less than 8 bar, more preferably less than 5 bar.

[0065] The present invention also provides a system as described herein.

[0066] The system of the present invention is intended for preparing a beverage and comprises a replaceable capsule, such as a capsule as described above, a beverage preparation device having a fluid dispensing device capable of supplying a quantity of a 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.

[0067] The system proposes using an exchangeable capsule integrating one or more of the above disclosed features in a beverage preparation device, wherein a second part of the brewing chamber of the beverage preparation device comprises an extraction plate for engaging the exchangeable capsule at a second end of the side wall when the brewing chamber holding the capsule is closed, the extraction plate comprising a tear surface that faces a carrier disc at the second end of the capsule in use, the carrier disc of the capsule used in the closed brewing chamber is not modified by the tear surface of the extraction plate, and wherein less than 10% of the outlet opening faces directly against the tear surface of the extraction plate in use.

[0068] More specifically, the tearing surface of the extraction plate may include pyramidal elements, and the distribution of the outlet openings is such that less than 10% of the outlet openings directly face the pyramidal elements of the tearing surface.

[0069] Advantageously, the distribution of the outlet openings across the carrier disc is also configured so that the distribution of the outlet openings is independent of the angular positioning of the carrier disc relative to the tearing surface of the extraction plate.

[0070] The extraction of the beverage ingredients may be an extraction carried out at a pressure of less than 8 bar, more preferably less than 5 bar.

[0071] The present invention further relates to the use of a capsule exhibiting one or more of the above-disclosed features, either alone or in a system exhibiting one or more of the above-disclosed features.

[0072] The disclosure of European Patent Application No. 20210284.4, filed November 27, 2020, is incorporated herein by reference.

[0073] Specific embodiments of the present invention are described in the detailed description below. These objects are achieved by the present invention, namely, a capsule, a system and a method for manufacturing the capsule. [Brief explanation of the drawings]

[0074] The present invention will be further described with reference to the following examples and drawings which form a part of this invention. The drawings are not intended to reflect in any way a limitation of the scope of the invention unless clearly and explicitly indicated. It will be understood that the invention as claimed is not intended to be limited in any way by these embodiments and drawings.

[0075] It should be noted that the figures are only schematic illustrations of embodiments of the invention, given as non-limiting examples.

[0076] Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: [Figure 1A] 1 is a perspective side view of a capsule sealed prior to use in a beverage preparation device according to the present invention; FIG. [Figure 1B] 1 is a perspective side view of a capsule with the lid partially removed, according to the present invention; FIG. [Figure 1C] FIG. 1 is a perspective side view of a capsule with the lid removed and ready to be used in a beverage preparation device according to the present invention; [Figure 2A] 1 is a schematic cross-sectional view of a capsule according to a first embodiment of the present invention. [Figure 2B] FIG. 2B is an enlarged view of the identified base of the capsule of FIG. 2A. [Figure 2C] FIG. 2B is a view of the carrier disk of the capsule of FIG. 2A before being assembled into the capsule. [Figure 3A]2B is a schematic diagram of the carrier disk of the capsule of FIG. 2A after assembly into a capsule having four crimp points according to the first proposed embodiment. [Figure 3B] 2B is a schematic diagram of the carrier disk of the capsule of FIG. 2A after assembly into a capsule having eight crimp points according to the first proposed embodiment. [Figure 4A] 3A-3C are schematic diagrams of carrier disks with different hole distribution patterns according to the present invention. [Figure 4B] 3A-3C are schematic diagrams of carrier disks with different hole distribution patterns according to the present invention. [Figure 4C] 3A-3C are schematic diagrams of carrier disks with different hole distribution patterns according to the present invention. [Figure 5] 1 is a table showing the evolution of the distribution of crema over time in an extracted coffee beverage for different disc versions according to the invention. [Figure 6A] FIG. 1 is a diagram of the proposed hole distribution pattern. [Figure 6B] 6B is a transparent overlay of the proposed hole distribution pattern of FIG. 6A with the tear surface of the extraction plate of the beverage preparation device at three different angular positions. [Figure 7] 1 is a schematic top view of a first set of outlet openings for a carrier disk obtained by a method according to an embodiment; [Figure 8] 3A and 3B are schematic top views of a first and second set of outlet openings for a carrier disk obtained by a method according to one embodiment; [Figure 9] 3A-3C are schematic top views of first, second and third sets of outlet openings for a carrier disk obtained by a method according to one embodiment; [Figure 10] 5A-5C are schematic top views of first to fourth sets of outlet openings for a carrier disk obtained by a method according to one embodiment. [Figure 11] 5A-5C are schematic top views of first to fifth sets of outlet openings for a carrier disk obtained by a method according to one embodiment. [Figure 12] 3A-3C are schematic top views of first to sixth sets of outlet openings for a carrier disk obtained by a method according to one embodiment; [Figure 13] 10A-10C are schematic top views of two sets of exit openings obtained by a cutting device cutting a sheet material by a method according to one embodiment. [Figure 14] A schematic top view of two sets of outlet openings of Figure 13 moved or displaced along the sheet movement direction relative to the cutting device, and two further sets of outlet openings obtained by the cutting device adjacent to the moved sets of outlet openings to cut the sheet material by a method according to one embodiment. [Figure 15] A schematic top view of the multiple sets of outlet openings of Figure 14 moved or displaced along the sheet movement direction relative to the cutting device, and two further sets of outlet openings obtained by the cutting device adjacent to the multiple sets of outlet openings so moved to cut the sheet material by a method according to one embodiment. [Figure 16] 16 is a schematic top view of the set of exit openings of FIG. 15 moved or displaced along the sheet movement direction relative to the cutting device, and two further sets of exit openings obtained by the cutting device cutting the sheet material by a method according to one embodiment, one of these sets of exit openings (in FIG. 16, the central set in the figure) being obtained for part of the multiple sets of exit openings so moved to form the exit openings of the carrier disk. [Figure 17] 17 is a schematic top view of the set of exit openings of FIG. 16 moved or displaced along the sheet movement direction relative to the cutting device and two further sets of exit openings obtained by a cutting device that cuts sheet material by a method according to one embodiment, one of these sets of exit openings being obtained adjacent to one of the sets of exit openings obtained according to FIG. 16 to form an exit opening of the carrier disk. [Figure 18]18 is a schematic top view of the multiple sets of outlet openings of FIG. 17 moved or displaced along the sheet movement direction relative to the cutting device and two further sets of outlet openings obtained by a cutting device that cuts sheet material by a method according to one embodiment, one of these sets of outlet openings being obtained adjacent to one of the multiple sets of outlet openings obtained according to FIG. 17 to form an outlet opening of the carrier disk. [Figure 19] 1 is a schematic top view of an extract of a sheet material from which multiple carrier disks can be obtained. [Figure 20] 1 is a schematic side view of an exemplary manufacturing line used in a method according to one embodiment. [Figure 21] 1 is a schematic cross-sectional side view of a portion of a cutting device during a method according to one embodiment. [Figure 22] 1A-1C are different schematic cross-sectional side views illustrating different stages in punching a sheet material to obtain an exit opening in a method according to one embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0077] As used herein, the terms "comprises," "comprising," and similar words should not be construed in an exclusive or exhaustive sense. In other words, they are intended to mean "including, but not limited to."

[0078] Any reference herein to a prior art document should not be taken as an acknowledgement that such prior art is well known or forms part of the common general knowledge in the art.

[0079] Figure 1A shows a capsule 1 prior to use in a beverage preparation device, defined as a storage state. With reference to Figure 2, the capsule 1 of Figure 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 that closes the interior space at a first end of the side wall of the capsule body 2. A flange 4 extends radially outward from a second end of the capsule body side wall 2a. At the second end of the side wall, the capsule body 2 has an open filling surface.

[0080] As is customary, the capsule body 2 is food-grade and includes a lacquer layer or polymer film layer (not shown) applied to the inside of the capsule body.

[0081] The capsule further comprises a lid 5 which is attached to a flange 4 of the capsule body, thereby sealing the capsule. The lid 5 may be manually removed from the capsule by pulling a free pull tab 6. In this case, the pull tab 6 is integral with and protrudes from the lid 5, although alternative solutions are available.

[0082] The lid 5 is a flexible sheet foil made of aluminum with a heat-seal lacquer or polymer layer on the sealing side.

[0083] If the lid 5 includes a lacquer layer on its sealing side, the thickness of the lacquer layer may be 0.003 mm to 0.03 mm. If the lid 5 includes a polymer layer on the sealing side, the thickness of the polymer layer may be 0.01 mm to 0.05 mm.

[0084] The lid 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 a layer of adhesive material, which may for example be a heat seal lacquer layer or a polymer film layer.

[0085] As an example, the sealing layer forming adhesive material may be a layer of 0.003 mm to 0.03 mm.

[0086] The layer of adhesive material allows removal of the lid 5 from the flange 4 of the capsule 1 without damaging the capsule.

[0087] The interior space of the capsule is filled with beverage ingredients before the capsule is closed. In this case, the capsule is filled with a coffee bed of roast and ground coffee before the capsule is sealed with the lid 5 in order to maintain the freshness of the roast and ground coffee. The weight of the coffee ranges from 4g to 15g depending on the size of the capsule. However, tea, milk or chocolate ingredients can also be envisaged.

[0088] FIG. 1B shows the capsule of FIG. 1A with the lid 5 partially removed by tearing off the pull tab 6, while FIG. 1C shows the same capsule with the lid 5 completely removed. As can be seen, the second end (filling side) of the capsule is no longer closed, revealing a membrane defined as a carrier disc 7 on the inside of the capsule. The carrier disc 7 comprises a plurality of preformed outlet openings (or holes) 8 for the beverage (here, coffee) to be prepared in the beverage preparation device. The capsule also comprises mechanical deformations 11a, 11b, 11c... at the junction between the side wall 2a and the flange 4, which holds the carrier disc 7 within the capsule's interior space. Four mechanical deformations 11 are visible in FIG. 1B. These mechanical deformations 11a, 11b, 11c... are also visible on the capsule of FIG. 1C, so that in fact eight mechanical deformations can be observed. These local deformations are achieved using a crimping process. Their function and the manner in which they are implemented are explained in connection with FIG. 2A and below.

[0089] The pre-formed outlet opening 8 of the carrier disc 7 is covered by the capsule lid 5, thereby closing the capsule and maintaining an airtight seal of the capsule's interior space to ensure the freshness of the beverage ingredients within the capsule during storage.

[0090] As can be seen in the cross-sectional views of various embodiments of the capsule of the present invention (see e.g. Fig. 2A), the capsule further comprises a filter element 9 in the interior space of the capsule, which is arranged between the coffee bed and the carrier disc 7. The filter element 9 prevents solid particles of the beverage ingredients, such as coffee particles or tea leaves, from escaping from the capsule into the end consumer's cup during extraction.

[0091] The capsule body 2 and the lid 5 may each be made primarily from aluminium, however other materials may be envisaged for the capsule body and the lid.

[0092] For example, the capsule body and lid may be made of a plastic polymer material, or the capsule body and lid may be made of a paper-based material.

[0093] As will be appreciated, the capsules are brewed using a conventional high-pressure beverage preparation device compatible with conventional Nespresso® coffee capsules, the beverage preparation device comprising 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 comprising an extraction plate presenting a tear surface for engaging the capsule at a second end opposite the base wall of the capsule.

[0094] To summarize the conventional brewing process of a closed capsule in a beverage preparation device, the capsule is inserted into the brewing chamber of the beverage preparation device. A fluid dispensing device supplies a quantity of fluid, such as water, to the capsule through the base wall 3 within the capsule to infuse and then extract the coffee. As pressure within the capsule increases, the capsule's lid comes into contact with the tear surface of the brewing plate and is deformed by said tear surface, leading to the formation of an opening that allows the coffee to flow out of the capsule.

[0095] The formation of an outlet opening in the surface of the lid by the interaction of the lid with the tear surface to allow the coffee to flow out is involved in the formation of foam and cream in the brewing process.

[0096] The use of a conventional capsule (closed capsule) with the above process results in coffee extraction at pressures between 8 bar and 20 bar.

[0097] In the brewing process for a capsule, the capsule lid is removed before inserting the capsule into the brewing chamber of the beverage preparation device. A fluid dispensing device supplies a quantity of fluid, such as water, to the capsule through the base wall 3 within the capsule to infuse and then extract the coffee. The extracted coffee passes through a filter element 9 and then flows out through the outlet opening of the carrier disc 7. During brewing, the carrier disc 7 (which is at a distance from the flange of the capsule) is not intended to come into contact with the tearing surface of the brewing plate of the beverage preparation device. The carrier disc 7 is not altered by tearing during brewing of the capsule (as in the case of brewing of conventional closed capsules, where the capsule membrane is torn on the tearing surface of the brewing plate, as explained in the previous section).

[0098] The use of a capsule (in a conventional beverage preparation device) results in coffee extraction at pressures between 0.1 bar and 8 bar, depending on the amount of coffee in the capsule and the filter element design.

[0099] Due to the fact that before use in the beverage preparation device, the lid is removed from the capsule and the carrier disc is placed in the capsule (see e.g. Figure 2A), the carrier is not intended to come into contact with the tear surface of the extraction plate and therefore will not be deformed by said tear surface.

[0100] More specifically, when using the capsule 1 in a beverage preparation device to prepare coffee, a user removes the lid 5 by pulling and peeling off the pull-tab 6 before inserting the capsule into a beverage preparation machine. The base wall 3 of the capsule body 2 is further pierced and opened by a piercing means of the beverage preparation device to supply water under pressure into the capsule for preparation of a coffee beverage.

[0101] The fact that the capsule is not closed when used in a beverage preparation device (lid 5 is removed and the outlet opening is accessible) limits the extraction pressure that builds up in the capsule (0.1 to 6 bar) and limits the formation of foam and cream during extraction.

[0102] Therefore, since there is no pressure build-up and sudden pressure drop in the interaction between the coffee / lid / opening element(s) and the tearing surface of the brewing plate of the beverage preparation device (as with the use of conventional capsules), the resulting coffee in the cup has little or no crema.

[0103] The capsules make it possible to prepare coffee, tea, milk or chocolate without crema, depending on the beverage ingredients in the capsule.

[0104] 2A shows a first embodiment of a capsule. As disclosed, the capsule comprises a carrier disc 7 (i.e., a perforated carrier disc) within an interior space, which is provided with a plurality of pre-formed exit openings 8.

[0105] As shown in FIG. 2B, an enlarged cross-sectional view of a selected bottom portion of FIG. 2A, the carrier disk 7 is positioned within the capsule at a distance of 0.1 mm to 2 mm from the lid 5, which is sealed onto the flange 4.

[0106] This gap between the capsule lid 5 (and therefore the flange 4 after the lid is removed for brewing) and the carrier disc 7 provides a recess so that if the carrier disc 7 flexes during the brewing process, the carrier disc 7 does not come into a tear interface with the tear surface of the brewing plate of the beverage preparation device.

[0107] The carrier disc 7 may be a substantially circular piece of material as shown in FIG. 2C, with a diameter approximately equal to the inner diameter of the capsule where the carrier disc 7 will be placed / inserted / maintained depending on the assembly process.

[0108] Therefore, in the proposed embodiment, the diameter of the carrier disc 7 may be approximately 29.5 to 30.5 mm.

[0109] In the proposed embodiment, the carrier disc may be made of aluminum, its thickness may be about 0.3 mm, but may vary between 0.1 mm and 1 mm.

[0110] The carrier disc may be made of aluminium, and in a preferred solution, such as that shown in the figures, the capsule body, lid and carrier disc are each made primarily from aluminium.

[0111] In the presented solution, the carrier disc 7 is maintained inside the capsule 1 thanks to a local mechanical deformation 11 made on the capsule at the junction between the side wall 2a of the capsule 1 and the flange 4. One mechanical deformation 11 can be seen in the detailed cross-sectional view of Figure 2B. The mechanical deformation is in the form of a crimp point 11 and is located on the side of the opening face of the capsule, opposite the base wall 3.

[0112] Since the capsule is made of a ductile material, preferably aluminium, the mechanical deformation caused by the crimping results in a local reduction in diameter, which makes it possible to hold the carrier disc 7 (and filter) inside the capsule, which in turn holds the carrier disc within the capsule 1.

[0113] Here, during the manufacturing process, a step is performed on the capsule prior to closing the capsule with the lid 5, in which the capsule is mechanically deformed at the junction of the flange 4 and the side wall 2a leading to the crimp point 11.

[0114] Between 2 and 10 crimp points, crimp points 11 (also seen in Figure 1C), are angularly distributed around the periphery of the capsule's open face at the junction of the capsule's flange and side wall.

[0115] Taking into account the tooling used to create the crimp points, the crimp points 11 are preferably evenly distributed around the periphery of the open face of the capsule.

[0116] Additionally, the crimp point 11 may have a rounded crimp imprint depending on the crimping tool used.

[0117] In the alternative, the carrier disc 7 may be made of plastic or a laminate film including, for example, a polyolefin such as polypropylene, polyethylene, or any other semi-crystalline polymer. The carrier disc 7 may also be made of a paper-based material, such as coated paper, laminated paper, or molded paper.

[0118] As can be seen in Figure 2C, the preformed outlet openings 8 can be circular openings evenly distributed on the surface of the carrier disc. This even distribution of the outlet openings ensures an even flow of coffee out of the capsule 1. This also helps to avoid the creation of channels through the beverage (coffee bed) in the capsule.

[0119] The openings may have a diameter set at about 0.75 mm to 1 mm, although the diameter may vary between 0.4 mm and 3 mm, and most preferably between 0.5 mm and 1.3 mm.

[0120] The number of preformed outlet openings may vary depending on the size of the capsule (and the size of the carrier disc) and how fast coffee delivery is desired. In the disclosed embodiment, the carrier disc 7 comprises between 50 and 150 openings, preferably about 90, and in the embodiment shown about 100 outlet openings.

[0121] In an alternative embodiment, the pre-formed exit opening may be oval.

[0122] As presented, the capsule may further comprise a filter element 9, which is placed on the ingredient bed (e.g. coffee bed) after filling of the capsule during a possible assembly process, with the carrier disc 7 being placed between the filter element and the lid 5. In an alternative assembly process, the filter is assembled on the carrier disc and both elements are inserted on the ingredient bed in the capsule.

[0123] As shown in the enlarged view of Figure 2B, the capsule is inverted and the filter element 9 is positioned on the carrier disc 7. The filter element is then supported by the carrier disc 7 within the capsule. The filter is kept flat within the capsule and does not come into contact with the tear surface of the brewing plate of the beverage preparation device during brewing.

[0124] The use of a two-piece design may allow for the use of non-sealable filter materials, which may be an advantage for sustainability.

[0125] As proposed in this embodiment, the filter element 9 is circular with a diameter smaller than that of the carrier disc 7, ie between 28 mm and 30.5 mm, generally 0.1 mm smaller than the disc carrier.

[0126] However, in alternative embodiments, the diameter of the filter element 9 may be similar to the diameter of the carrier disc 7 .

[0127] The filter element 9 may be made of a nonwoven material adapted to prevent / inhibit the coffee drain from passing too slowly or too quickly during extraction of the beverage, in order to avoid the formation of a crema layer and in order to avoid the coffee drain passing through the disc carrier directly into the cup.

[0128] The filter element 9 of the proposed embodiment may have a thickness of 20-300 μm, an air permeability according to ISO 9237 in the range of 100-5000 L / m / s and a weight in the range of 5-600 g / m. It may for example be a paper-based filter element.

[0129] The filter element may include a layer of nonwoven material connected to another filtering layer by any known means.

[0130] In the proposed embodiment of Figures 2A-2C, the filter element 9 and the carrier disc 7 are separate elements arranged on top of each other. However, they may also be assembled together, for example by gluing or any other means. This modifies the assembly process within the capsule, since the insertion of the filter and the carrier disc is carried out in one step. The filter element 9 and the carrier disc 7 may together form one part.

[0131] The proposed circular carrier disc 7 may have a tapered shape around the periphery of the carrier disc 7 to fit (force-fit) into a capsule having a frusto-conical shape, however other alternative shapes and arrangements of the carrier disc within the capsule may be envisaged.

[0132] Preferably, the carrier disc 7 and the filter element 9 remain in place in the capsule when the lid 5 is removed and the capsule 1 is brewed in a beverage preparation machine. Several assembly processes may be considered and will be disclosed later in connection with proposed embodiments of the capsule.

[0133] In an alternative embodiment not shown, the carrier disc may be made of plastic or laminated plastic elements, in this situation the assembly process of the carrier disc in the capsule remains similar.

[0134] Figures 3A and 3B show the capsule of Figure 2A (viewed from the open side of the capsule) after the carrier disc 7 has been inserted into the capsule and assembled into the capsule at four and eight crimp points, respectively, before closing the open side of the capsule by attaching the lid. As can be seen, the distribution pattern of the holes in the carrier disc 7 is the same, but at two different angular positions.

[0135] The number of crimp points (mechanical deformations) may vary between 2 and 10 to enable sufficient and efficient retention of the carrier disc 7 (and the filter element 9 supported by the carrier disc) within the capsule 1.

[0136] The crimp points 11 are angularly distributed around the periphery of the capsule's open face at the junction between the capsule's side wall 2a and the flange 4. Preferably, as presented herein, the crimp points are evenly distributed along the periphery of the capsule's open face.

[0137] The tools currently used during the step of mechanically deforming the capsule have rounded end geometries that allow the crimp point to have a substantially rounded crimp imprint.

[0138] Figures 4A, 4B and 4C show different satisfactory versions of the carrier disc 7, having different hole distributions, to be inserted into the interior space of the capsule body 2. As can already be seen in the previous figures, the carrier disc 7 comprises a plurality of pre-formed outlet openings 8 suitable for expelling the prepared beverage from the interior space of the capsule towards the outside of the capsule when the capsule is used in a beverage preparation device.

[0139] The carrier disc 7 may be a preferably circular aluminum disc with a diameter that may be set to 30 mm + / - 3 mm, however the diameter of the carrier disc may be between 28.5 mm and 30.5 mm depending on the size and / or structure of the capsule.

[0140] The thickness of the carrier disc 7 used in the capsule of Figure 2A may be approximately 0.3 mm. However, the thickness of the carrier disc may vary. The thickness may be 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.

[0141] The carrier disc may have a void space 10 that is free of outlet openings on its periphery over a distance of at least 0.5 mm to avoid some outlet openings being damaged during assembly and / or covered by the crimp points (seen in Figures 3A and 3B). The void space 10 is particularly visible in Figure 4A.

[0142] As shown in the figure, the exit openings 8 are pre-formed, calibrated circular openings. The exit openings 8 are preferably uniformly distributed on the surface of the carrier disc 7, and each exit opening may be spaced apart from the adjacent exit opening(s) by a distance of 2.5 mm, although this distance may be between 0.5 mm and 3 mm. The pattern of the opening distribution may appear as a grid or matrix.

[0143] In the proposed embodiment, the outlet opening 8 may have a diameter set at about 1 mm. However, the outlet opening may have a diameter between 0.4 mm and 3 mm, preferably between 0.5 mm and 1.3 mm.

[0144] In an alternative embodiment not shown, the outlet opening is an oval hole.

[0145] The manufacturing process for carrier discs with a specific distribution of outlet openings can be carried out using a metal foil punching technique, which uses a die to punch material through a matrix, although other techniques known to those skilled in the art can also be used.

[0146] The proposed carrier disc 7 of Figures 4A, 4B and 4C may comprise 50 to 150 outlet openings 8 with an open surface ratio of the carrier disc preferably higher than 4%.

[0147] The open surface ratio is defined as the ratio of the sum of the surface of the holes to the surface of the carrier disc, as follows:

[0148]

number

[0149] In the present invention, the first requirement is to obtain a filter-like coffee with as little crema as possible by extracting a disposable capsule in a conventional Nespresso® machine. In some cases, even if some crema occurs, this crema is expected to disappear after 2 minutes.

[0150] The table below (Table 1) shows that not only the number of outlet openings 8 (also called holes) but also the size of the holes and the size of the carrier disc are important and lead to the open surface ratio.

[0151] The tests were carried out on a carrier disc having a diameter of about 30 mm.

[0152] The data presented in Table 1 show the following:

[0153] Tests 1, 2 and 5-7 were carried out with a number of holes greater than 50 and an open surface area greater than 4%. The results were considered satisfactory, as no residual crema was observed in the resulting coffee beverage 2 minutes after extraction.

[0154] In test 3, when the number of holes was less than 50 and the open surface ratio was less than 4%, the extracted coffee contained a residual crema after 2 minutes. The final extracted coffee was similar to that obtained from high-pressure extraction of closed capsules.

[0155] In test 4, when the number of holes was less than 50, e.g. 2, and the open surface rate was more than 4%, coffee extraction was possible, but the coffee was unsatisfactory with coffee particles in the cup due to technical problems related to the perforation of the filter on the tearing surface of the machine. The extraction process was similar to conventional high-pressure sealed capsule extraction, which involves tearing of the capsule element (here the filter) on the tearing surface of the extraction plate of the beverage machine.

[0156] [Table 1]

[0157] Referring to Figure 5, a table is presented which shows, for different carrier disc versions and the resulting extracted coffee (photographed from above in the coffee cup) 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.

[0158] As can be seen, the carrier discs corresponding to the reference and the carrier discs with more than 50 holes show no or very little crema remaining in the cup at t0+1 min.

[0159] The carrier disc containing 42 holes (V2.1.7) shows a crema remaining in the coffee at t0+5 min, which therefore does not correspond to the expected filter-like coffee, and therefore this carrier disc cannot be retained for the specific purpose of producing filter-like coffee using disposable capsules in a conventional Nespresso® machine.

[0160] From the above results (Figure 5 and Table 1), the carrier disc preferably comprises 70 to 120 outlet openings, most preferably 85 to 110 outlet openings.

[0161] With regard to the open surface ratio of the carrier disc, the open surface ratio may be higher than 4%, preferably 4% to 15%, more preferably 5% to 12%.

[0162] For example, for openings with a diameter of 0.3 mm evenly distributed on a carrier disk with a diameter of about 30 mm: An open surface ratio of 5% results in approximately 200 holes. An open surface ratio of 10% results in approximately 995 holes. An open surface ratio of 15% results in approximately 1493 holes.

[0163] With reference to Figures 6A and 6B, the proposed carrier disc 7 and its different orientations relative to the tear surface 12 of the brewing chamber of the beverage preparation device are shown.

[0164] The presented carrier disc 7 may have a diameter of about 30 mm and is provided with 96 outlet openings distributed over the entire surface of the carrier disc, except for void spaces 10 on its periphery which are free of outlet openings 8 for a distance of about 1 mm.

[0165] The open surface ratio of the carrier disk is about 9.3%.

[0166] In addition to the above parameters, as explained, the capsule 1 incorporating the particular carrier disc 7 is intended for extraction in a beverage preparation device or machine (not shown).

[0167] The beverage preparation device, not shown, comprises a fluid dispensing device capable of supplying a quantity of fluid, such as water, to a capsule at a pressure between 0.1 bar and 20 bar, and a brewing chamber having 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 for engaging a replaceable capsule at a second end of the side wall when the brewing chamber for holding the capsule is closed, the extraction plate comprising a tear surface with pyramidal elements facing the second end of the capsule in use.

[0168] Therefore, in the brewing process of the capsule of the present invention, the lid of the capsule is removed before inserting the capsule into the brewing chamber of the beverage preparation device, with the capsule, more particularly the carrier disc 7, facing the tearing surface (in the form of a pyramidal element) of the brewing plate of the beverage preparation device.

[0169] During the extraction process, water is injected into the capsule and mixed with the coffee ingredients placed in the capsule's internal space. With the lid removed, the coffee ingredients are extracted at a pressure of less than 8 bar, more preferably less than 5 bar.

[0170] The coffee beverage then passes through a filter and aims to exit the capsule through an outlet opening.

[0171] During extraction, even if the carrier disc does not have a tearing interaction with the tearing surface of the extraction plate, it is important that the extracted coffee is not prevented from exiting the carrier disc and is not affected by the tearing surface near the extraction plate.

[0172] In the proposed pattern of outlet opening distribution, less than 10% of the outlet openings 8 of the carrier disc 7 face directly to the tear surface of the extraction plate.

[0173] The pattern is configured so that the features are independent of the angular positioning of the carrier disk relative to the tear surface of the extraction plate.

[0174] Figure 6B illustrates a transparent superposition of the carrier disk and the tear surface of the extraction plate showing the proposed hole distribution pattern of Figure 6A at three different angular positions, 0°, 20°, and 30°, respectively.

[0175] The number of blocked holes was counted for each angular position of the carrier disc 7. At 0°, four holes were blocked, at 20°, eight holes were blocked, and at 30°, six holes were blocked.

[0176] Whatever the angular position of the carrier disc relative to the tearing surface of the brewing plate, an optimized regular flow of brewed coffee is obtained thanks to the low number of blocked holes (less than 10%).

[0177] As explained above, the number of openings 8 in the opening of the carrier disc 7 and the diameter of each of these openings 8 are important in order to ensure that no, or at least only a small amount of, crema remains in the resulting beverage. It is therefore desirable to produce a particularly large number of these openings 8 with high precision, i.e. in a precise manner, in the carrier 7. The following embodiment of the method, which will be explained with reference to Figures 7 to 22, achieves this objective very easily.

[0178] FIG. 7 illustrates a sheet material 70 from which a carrier disk 7 having outlet openings 8 can be obtained. As illustrated, a cutting device (not shown) cuts the sheet material to obtain a first set 8.1 of outlet openings 8. The first set 8.1 is shown in black. As illustrated, the outlet openings of the first set 8.1 can be unevenly distributed, for example, such 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, where the subsets 8.11 and 8.12 may be spaced apart by a distance 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 respective outlet openings can be uniformly distributed. In other words, the uneven distribution of the outlet openings of the first set 8.1 can be caused by the distance between the subsets 8.11 and 8.12. The outlet openings in the first set 8.1 can be arranged according to a matrix or grid, such as along multiple columns and multiple rows.

[0179] As shown in FIG. 7 , sheet material 70 includes (first) alignment openings 71. In this embodiment, alignment openings 71 are cut by a cutting device. For example, by cutting sheet material 70 to obtain first set 8.1, the cutting device simultaneously cuts sheet material 70 to obtain alignment openings 71. In an alternative embodiment, alignment openings 71 may be pre-fabricated in sheet material 70 such that the cutting device does not need to manufacture alignment openings 71. Alignment openings 71 are not limited to a particular shape. For example, alignment openings 71 may have a circular shape and / or a diameter larger than the diameter of each of exit openings 8.

[0180] FIG. 8 shows sheet material 70 having a second set 8.2 of exit openings 8. The second set 8.2 is indicated by diagonal hatching. As shown in FIG. 7, after cutting sheet material 70 to obtain first set 8.1, sheet material 70, and thus first set 8.1, can be moved along a specified distance in direction 75 relative to the cutting device and then stopped. That is, sheet material 70 can be moved intermittently. Then, in an alignment step, alignment elements 101 (e.g., in the form of pins), which can be part of the cutting device, are moved so as to extend through the first alignment openings 71. This allows first set 8.1 to be precisely aligned (centered, positioned, etc.) relative to the cutting device. In an optional step preceding alignment with alignment openings 71, pre-alignment of alignment openings 71 relative to alignment elements 101 can be performed. For example, the optical device can (automatically) measure the distance between alignment opening 71 and alignment element 101, and then advance sheet material 70 along this distance so that alignment opening 71 is approximately flush with alignment element 101. In other words, pre-alignment of the sheet material relative to the alignment element can be performed by (automatic) vision control.

[0181] 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 be adjacent to the first set 8.1, preferably such 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. Thus, 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, and the subsets 8.21 and 8.22 may be spaced apart from each other. As shown, the second subset 8.22 may be located between subsets 8.11 and 8.12 of the first set 8.1.

[0182] As shown in FIG. 8 , sheet material 70 may include second alignment openings 72. Second alignment openings 72 may be cut by a cutting device. For example, by cutting sheet material 70 to obtain second set 8.2, the cutting device simultaneously cuts sheet material 70 to obtain second alignment openings 72. In an alternative embodiment, alignment openings 72 may be pre-fabricated in sheet material 70 such that a cutting device is not required to manufacture alignment openings 72. Alignment openings 72 may be identical to alignment openings 71. Alignment openings 72 are not limited to a particular shape. For example, alignment openings 72 may have a circular shape and / or a diameter greater than the diameter of each of exit openings 8.

[0183] FIG. 9 shows sheet material 70 having a third set 8.3 of exit openings 8. The third set 8.3 is indicated by hatching that is the opposite of the hatching that indicates the second set 8.2. As shown in FIG. 8 , after cutting sheet material 70 to obtain second set 8.2, sheet material 70, and thus first set 8.1 and second set 8.2, may be moved along a specified distance in direction 75 relative to the cutting device and then stopped. Then, in an alignment step, alignment element 101 is moved to extend through first alignment openings 71. Thereby, first set 8.1 and second set 8.2 are precisely aligned (e.g., centered) relative to the cutting device. In an optional step preceding alignment, pre-alignment of alignment openings 71 relative to alignment element 101 may be performed, similar to pre-alignment of alignment openings 71, for example, by using the optical device described above.

[0184] After the alignment step, the cutting device cuts the sheet material 70 to obtain the third set 8.3. As shown, at least a portion of the third set 8.3 may be adjacent to the second set 8.2, preferably such 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 identical to the hole patterns of the first set 8.1 and the second set 8.2, respectively. Thus, 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, and the subsets 8.31 and 8.32 may be spaced apart from each other. As shown, the second subset 8.32 may be located between subsets 8.11 and 8.22.

[0185] As shown in FIG. 9 , sheet material 70 may include third alignment opening 73. Third alignment opening 72 may be cut by a cutting device. For example, by cutting sheet material 70 to obtain third set 8.3, the cutting device simultaneously cuts sheet material 70 to obtain third alignment opening 73. In an alternative embodiment, alignment opening 73 may be pre-fabricated in sheet material 70 such that the cutting device does not need to manufacture alignment opening 73. Alignment opening 73 may be identical to alignment openings 71 and 72, respectively. Alignment opening 73 is not limited to a particular shape. For example, alignment opening 73 may have a circular shape and / or a diameter larger than the diameter of each of exit openings 8.

[0186] The steps described with respect to Figures 7 to 9 may be repeated to provide further sets of outlet openings, specifically as follows. moving the sheet material 70, and thus the already obtained set, along a defined distance in the direction 75 relative to the cutting device; stopping the sheet material 70; Aligning the already obtained set with respect to the cutting device by means of an alignment element 101 that moves to extend through an alignment opening (e.g. obtained in a previous cutting step); Cutting the sheet material 70 having the plurality of sets of so aligned exit openings with a cutting device to obtain further sets of exit openings including aligned openings.

[0187] The distance that sheet material 70 and first set 8.1 move relative to the cutting device to produce second set 8.2 (i.e., from the configuration of FIG. 7 to the configuration of FIG. 8) may correspond to (i.e., may be equal to) the distance that sheet material 70 and first set 8.1 and second set 8.2 move relative to the cutting device to produce third set 8.3 (i.e., from the configuration of FIG. 8 to the configuration of FIG. 9). In other words, to obtain first set 8.1 through third set 8.3, sheet material 70 may be moved intermittently equal distances relative to the cutting device, i.e., distances that are essentially the same as each other.

[0188] FIG. 10 shows sheet material 70 having a fourth set 8.4 of exit openings 8. The fourth set 8.4 is shown in white with a black outline. As shown in FIG. 8 , after cutting sheet material 70 to obtain third set 8.3, sheet material 70, and thus sets 8.1, 8.2, and 8.3, can be moved along a specified distance in direction 75 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 alignment element 101) is moved to extend through the first alignment openings 71. Sets 8.1, 8.2, and 8.3 are thereby precisely aligned (e.g., centered) relative to the cutting device. In an optional step preceding alignment, pre-alignment of alignment openings 71 relative to alignment element 102 can be performed, similar to the pre-alignment of alignment openings 71 described above, for example, by using an optical device as described above.

[0189] After the alignment step, the cutting device cuts the sheet material 70 to obtain the fourth set 8.4. As shown, at least a portion of the fourth set 8.4 may be preferably disposed between the outlet openings of the first set 8.1, such as the first subset 8.11, such 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 section of the sheet material 70, and the cutting device cuts this section to obtain at least one outlet opening of the fourth set 8.4 disposed between the outlet openings of the first set 8.1. In particular, an outlet opening 8 of the fourth set 8.4 that is disposed between outlet openings 8 of the first set 8.1 may be spaced apart from an adjacent opening 8 of the first set 8.1 by a distance of 0.5 mm to 3 mm, more preferably 1 mm to 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 an outlet opening 8 of the fourth set 8.4 that is disposed between outlet openings 8 of the first set 8.1 and an opening 8 of the first set 8.1 that is adjacent to that outlet opening 8 of the fourth set 8.4.

[0190] The fourth set 8.4 is not limited to a particular 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) uniformly distributed, for example, so that the fourth set 8.4 does not include any subsets spaced apart by a distance greater than the distance between adjacent outlet openings of the fourth set 8.4. The outlet openings of the fourth set 8.4 may also be arranged according to a matrix or grid, such as along multiple columns and multiple rows, with the number of rows preferably being greater than the number of columns.

[0191] The method is not limited to obtaining the fourth set 8.4 after obtaining the third set 8.3. For example, the fourth set 8.4 may be obtained immediately after the first set 8.1 and / or the second set 8.2 are obtained, with the fourth set 8.4 being the second set of outlet openings or the third set of outlet openings, respectively.

[0192] FIG. 11 shows sheet material 70 with a fifth set 8.5 of exit openings 8. The fifth set 8.5 is indicated by vertical hatching. As shown in FIG. 10, after cutting sheet material 70 to obtain fourth set 8.4, sheet material 70, and thus sets 8.1-8.4, may be moved along a predetermined distance in direction 75 relative to the cutting device and then stopped. Then, in an alignment step, alignment element 102 is moved to extend through second alignment opening 72, thereby precisely aligning sets 8.1-8.4 relative to the cutting device. In an optional step preceding alignment, pre-alignment of alignment opening 72 relative to alignment element 102 may be performed, similar to the pre-alignment of alignment opening 71 described above, for example, by using an optical device as described above.

[0193] After the alignment step, the cutting device cuts the sheet material 70 to obtain a fifth set 8.5. As shown, at least a portion of the fifth set 8.5 may be preferably disposed between the outlet openings of the second set 8.2, such as the first subset 8.21, such 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 may 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 may have the same hole pattern as the fourth set 8.4. In other words, the exit openings of the second set 8.2 may be surrounded by a section of the sheet material 70, and the cutting device cuts this section to obtain at least one exit opening of the fifth set 8.5 arranged between the exit openings of the second set 8.2.

[0194] FIG. 12 shows sheet material 70 with a sixth set 8.6 of exit openings 8. As shown in FIG. 11, after cutting sheet material 70 to obtain fifth set 8.5, sheet material 70, and thus sets 8.1-8.5, may be moved along a predetermined distance in direction 75 relative to the cutting device and then stopped. Then, in an alignment step, alignment element 102 is moved to extend through third alignment opening 73, thereby precisely aligning sets 8.1-8.5 relative to the cutting device. In an optional step preceding alignment, pre-alignment of alignment opening 73 relative to alignment element 102 may be performed, similar to the pre-alignment of alignment opening 71 described above, for example, by using an optical device as described above.

[0195] After the alignment step, the cutting device cuts the sheet material 70 to obtain the sixth set 8.6. As shown, at least a portion of the sixth set 8.6 may be preferably disposed between the outlet openings of the third set 8.3, such as the first subset 8.31, such 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 may be obtained between a portion of 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. In other words, the outlet openings of the third set 8.3 may be surrounded by a section of the sheet material 70, and the cutting device cuts this section to obtain at least one outlet opening of the sixth set 8.6 disposed between the outlet openings of the third set 8.3.

[0196] 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.

[0197] The steps described with respect to Figures 10-12 may be repeated to provide further sets of outlet openings, specifically as follows. moving the sheet material 70, and thus the already obtained set, along a defined distance in the direction 75 relative to the cutting device; stopping the sheet material 70; Aligning the previously obtained set with respect to the cutting device by means of an alignment element 102 that moves to extend through an alignment opening (e.g., obtained in one of the cutting steps to obtain the first to third sets); and Cutting the sheet material 70 having the multiple sets of exit openings so aligned by a cutting device to obtain further sets of exit openings.

[0198] The distance that sheet material 70 and fourth set 8.4 move relative to the cutting device to produce fifth set 8.5 (i.e., from the configuration of FIG. 10 to the configuration of FIG. 11) may correspond to (i.e., may be equal to) the distance that sheet material 70 and fourth set 8.4 and fifth set 8.5 move relative to the cutting device to produce sixth set 8.6 (i.e., from the configuration of FIG. 11 to the configuration of FIG. 12). In other words, to obtain fourth set 8.4 through sixth set 8.6, sheet material 70 may be moved intermittently equal distances relative to the cutting device, i.e., distances that are essentially identical to one another.

[0199] Sheet material 70 may be moved intermittently over different distances to provide sets of exit openings. For example, the (second) distance that sheet material 70 having one or more sets 8.1-8.3 moves relative to the cutting device to produce fourth set 8.4 (e.g., from the arrangement of FIG. 9 to the arrangement of FIG. 10) may be greater than the (first) distance that sheet material 70 and first set 8.1 move relative to the cutting device to produce second set 8.2, or the (first) distance that sheet material 70 having first set 8.1 and second set 8.2 moves relative to the cutting device to produce third set 8.3.

[0200] Specifically, 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 and / or spaced apart from the first cutting station. Specifically, by moving the sheet material 70 along a second distance, one or more sets of exit openings 8 obtained at the first cutting station are moved to a second cutting station where one or more further sets of exit 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 with respect to the first cutting station, and the second alignment element 102 may be arranged to align at least the first set 8.1 with respect to the second cutting station. The cutting stations may be arranged along the direction of movement of the sheet material.

[0201] Figures 13 to 18 show an embodiment in which the sheet material is moved intermittently at different distances. At each interruption in this intermittent movement, at least a cutting step (and preferably an alignment step) is performed to obtain two respective sets of outlet openings, such as one set through a first cutting station and another set through a second cutting station, as shown in Figures 13 to 18, respectively. In Figures 13 to 18, the sets 8.1 to 8.6 of outlet openings 8 are shown diagrammatically and simplified in the form of boxes. If a set does not have multiple subsets, the boxes correspond to the subsets or sets.

[0202] As shown in Figures 13-15, sheet material 70 is cut by a cutting device, specifically a first cutting station, to obtain first sets 8.1 through third sets 8.3, respectively, as described above with respect to Figures 7-9. Concurrently, sheet material 70 is cut by a cutting device, specifically a second cutting station, to obtain fourth sets 8.4 through sixth sets 8.6, respectively. Between the state shown in Figure 13 and the state shown in Figure 14, and between the state shown in Figure 14 and the state shown in Figure 15, sheet material 70 moves along the same distance relative to the cutting device.

[0203] As shown in Figures 16-18, the sheet material 70 is cut by a cutting device, in particular by the second cutting station, as described above with respect to Figures 10-12, respectively, to obtain the fourth set 8.4 to the sixth set 8.6 of outlet openings for the carrier disc 7. In parallel, the sheet material 70 is cut by a cutting device, in particular by the first cutting station, to obtain further sets of outlet openings that are at least partially used for further carrier discs 7. These further sets of outlet openings are obtained as described above with respect to Figures 7-9, respectively. Between the state shown in Figure 15 and the state shown in Figure 16, the sheet material 70, and thus the first set 8.1 to the third set 8.3, move along a distance that is greater than the distance between the state shown in Figures 13 and 14, or between the state shown in Figures 14 and 15. By this greater distance, the first set 8.1 to the third set 8.3 are positioned relative to the second cutting station to obtain the fourth set 8.4 to the sixth set 8.6. Between the state shown in Figure 16 and the state shown in Figure 17, and between the state shown in Figure 17 and the state shown in Figure 18, the sheet material 70 moves relative to the cutting device along the same distance.

[0204] As shown in Figure 18, at least two groups of alignment openings may be provided in a row extending parallel to the direction of movement 75 of the sheet material 70. Each group may be provided for the first and second sets of exit openings of one or more carrier disks. Each group includes at least one respective alignment opening 71, and preferably two or more respective alignment openings 71-73. Within each group, the respective alignment openings 71-73 may be equally spaced apart. The distance between adjacent groups may be different (e.g., greater) than the distance between adjacent alignment openings within the same group.

[0205] In an optional step of the method, a carrier disc 7 is obtained which comprises at least sets 8.1-8.6. According to one embodiment, an alignment element is used which extends through one of the one or more alignment openings, for example through alignment opening 71, to align sets 8.1-8.6 with a cutting device, in particular with a third cutting station of the cutting device. A cutting device, such as the third cutting station, then cuts the sheet material 70 to obtain a carrier disc 7 which comprises sets 8.1-8.6 of outlet openings 8 aligned in this way.

[0206] The sheet material 70 may be cut to obtain at least two sets of a plurality of outlet openings 8 for a corresponding plurality of carrier discs. The so-cut sheet material 70 may then be made suitable for transportation, such as being wound up to form a sheet roll, such as the sheet roll 76 shown in FIG. 21 . A sheet roll may then be prepared or supplied, and a plurality of carrier discs, each comprising at least two sets of a plurality of outlet openings 8, may be obtained from the sheet material 70. In other words, the result of the method for obtaining at least the outlet openings may be a reserve product for a plurality of carrier discs.

[0207] 19 shows an example of a sheet material 70. As shown, one or more registration openings may be arranged in rows extending parallel to the direction of movement of the sheet material. As shown, a plurality of carrier discs 8 may be manufactured or obtained from the sheet material 70. The plurality of carrier discs 8 may be obtained from the sheet material 70 such that, after obtaining the plurality of carrier discs 8 from the sheet material 70, corresponding cut-out sections are provided in the sheet material 70 according to the form of a matrix or grid, such as a plurality of rows (e.g., at least two rows, preferably at least five rows, more preferably at least ten rows), the rows extending parallel to the direction of movement of the sheet material 70.

[0208] The sheet material 70 may include one or more first rows each including a plurality of alignment openings 71-73, each extending parallel to the direction of movement of the sheet material 70, and one or more second rows each including a plurality of sets of exit openings for the plurality of carrier disks, each extending parallel to the direction of movement 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 ten. The alignment openings 71-73 (e.g., in each first row) may be arranged in groups, each of which includes at least one respective alignment opening 71, preferably two or more respective alignment openings 71-73 (e.g., depending on the number of cutting (e.g., punching) steps during the first manufacturing step, i.e., the step of obtaining a set of exit openings before obtaining the carrier disks in the second manufacturing step). In each group, the alignment openings 71-73 may be equally spaced. The distance between adjacent groups may be different (eg, larger) than the distance between adjacent alignment openings within the same group.

[0209] As shown in FIG. 20, the sheet material 70 may be provided as a sheet roll 76, and the cutting device may cut a portion of the sheet material 70 that is unfolded, ie, not curved, but is, for example, straight.

[0210] The method may further include providing a filter element 9, such as the filter element 9 described above.

[0211] At least a portion of the sheet material 70 may be placed between at least a portion of the cutting device and the capsule body 2 on which the carrier disc 7 and optionally the filter element 9 are disposed. For example, sheet material unwound from a sheet roll 76 may be placed between the cutting device and the capsule body 2 (when viewed in side view).

[0212] The method is not limited to a particular type of cutting or shearing device. The cutting device may be configured to cut the sheet material to obtain a large number of exit openings, such as 1,200, in a single step. The cutting device may include at least two cutting stations, each configured to cut the sheet material to obtain at least 100 exit openings, preferably 200 to 400, in a single step (e.g., in a single cutting step, such as during a single stroke). In one embodiment, the cutting device is a punching device. For example, the punching device may include a first punching station for cutting the sheet material 70 to obtain at least set 8.1 and a second punching station for cutting the sheet material 70 to obtain at least set 8.4. Each punching station may include a punch designed to obtain a hole pattern for each set of exit openings. The punch may include multiple punch elements corresponding in number and arrangement to the exit openings for each set of exit openings. Each punching station may include a die through which at least a portion of the punch can pass after passing through the sheet material 70. The die may comprise a plurality of die elements corresponding in number and arrangement to the exit openings and / or punch elements of each set of exit openings. The punching device may comprise a dedicated punching station for cutting the sheet material 70 to obtain carrier discs 8 comprising at least set 8.1 and at least set 8.4.

[0213] 21 shows an example of a punch element 110 used in one embodiment of the method to obtain one of the exit openings 8. The punch element 110 is positioned opposite a die 111 through which at least a portion of the punch element 110 can pass after passing through the sheet material 70. The sheet material 70 may be positioned between the die 111 and the punch element 110 before the punch element 110 passes through the sheet material 70 to cut it. The punching station may include a stripper 112 (e.g., in the form of a plate), and the sheet material 70 may be positioned below the stripper 112 or between the stripper 112 and the die 111.

[0214] FIG. 22 exemplarily illustrates a punching process using the arrangement of FIG. 21 . As illustrated, the punching process proceeds in four stages (a) through (d). In the first stage (a), the punch element 110 contacts the sheet material 70, thereby deforming the sheet material 70. Then, in stages (b) and (c), the punch element 70 cuts the sheet material 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 of the sheet element 70, the so-called punching slug, is ejected away from the sheet element 70, specifically downward, for example, into a die 111. When the punch element 110 moves upward again, it may pull the sheet element 70. In that case, a stripper 112 may be positioned to peel the sheet material 70 from the punch element 110.

[0215] Although the present invention has been described by example, it should be understood that variations and modifications can be made without departing from the scope of the invention as defined in the claims. Furthermore, where known equivalents exist for specific features, such equivalents are incorporated as if specifically referred to herein. [Explanation of symbols]

[0216] 1 capsule 2 Capsule body / 2a Side wall 3 Base wall 4 flanges 5 Lid 6 pull tab 7 Carrier Disk 8 outlet opening 8.1 First set of outlet openings 8.11 First Subset of First Set 8.12 Second Subset of First Set 8.2 Second set of outlet openings 8.21 First Subset of Second Set 8.22 Second subset of second set 8.3 Third set of outlet openings 8.31 First subset of the third set 8.32 Second subset of third set 8.4 Fourth set of exit openings 8.5 Fifth set of exit openings 8.6 Sixth set of exit openings 9 Filters 10 void space 11 Mechanical Deformation / Crimping 70 Sheet Material 71 first alignment opening 72 Second alignment opening 73 Third alignment opening 75 Sheet movement direction 76 Sheet Roll 101 first alignment element 102 second alignment element 110 punch elements 111 Die 112 Stripper

Claims

1. A method for obtaining at least an outlet opening (8) for a carrier disk (7) that can be provided in the internal space of a capsule (1) for preparing a beverage, wherein the outlet opening (8) is suitable for discharging the prepared beverage from the internal space toward the outside of the capsule (1) when the capsule (1) is used in a beverage preparation device, and the method is The steps include: preparing a sheet material (70) from which the carrier disc (7) having the outlet opening (8) can be obtained; The steps include cutting the sheet material (70) with a cutting device to obtain a first set of the exit openings (8), The steps include aligning the first set of the exit openings with respect to the cutting device using an alignment element (101) that extends through an alignment opening (71) provided in the sheet material (70), The step of cutting the sheet material (70) having the first set of outlet openings aligned in this manner with the cutting device to obtain a second set of outlet openings, A method comprising the step of moving the sheet material (70) intermittently at different distances relative to the cutting device.

2. The steps include aligning the multiple sets of the exit openings (8) with respect to the cutting device by the alignment element (101) extending through a further alignment opening (72) provided in the sheet material (70), The method according to claim 1, further comprising the step of cutting the sheet material (70) having the plurality of sets of the exit openings (8) aligned in this manner with the cutting device to obtain a further set of the exit openings (8).

3. The steps include aligning a plurality of sets of the exit openings (8) with respect to the cutting device by a further alignment element (102) extending through the alignment opening (71) provided in the sheet material (70), The method according to claim 1 or 2, further comprising the step of cutting the sheet material (70) having the plurality of sets of the exit openings (8) aligned in this manner with the cutting device to obtain an additional set of the exit openings (8).

4. The method according to claim 1 or 2, wherein at least a portion of the outlet openings (8) of one set of the outlet openings (8) is positioned between the outlet openings (8) of a corresponding set of the outlet openings (8).

5. The method according to claim 1 or 2, further comprising the step of cutting the sheet material with the cutting device to obtain the alignment opening (71).

6. The method according to claim 1 or 2, wherein the alignment opening (71) is obtained in the cutting step for obtaining the first set of the exit openings.

7. The method according to claim 1 or 2, further comprising the step of cutting the sheet material with the cutting device so that the carrier disc (7) comprises a plurality of sets of the exit openings (8) to obtain the carrier disc (7).

8. The method according to claim 7, wherein the obtained carrier disk (7) does not have an outlet opening (8) on its outer circumference over a distance of at least 1 mm, preferably 0.5 to 2.5 mm, and more preferably 1 to 2 mm.

9. The steps of aligning a plurality of sets of the exit openings (8) with respect to the cutting device by using alignment elements extending through the alignment opening (71) or other alignment openings (72, 73) provided in the sheet material (70), The method according to claim 1 or 2, further comprising the step of cutting the sheet material (70) with the cutting device so as to obtain the carrier disc (7) having a plurality of sets of the exit openings (8) aligned in that manner.

10. The method according to claim 1 or 2, wherein the cutting device is a punching device, and preferably the cutting of the first set and the second set of the exit openings is performed by the same punch or by different punches, respectively.

11. The method according to claim 1 or 2, wherein one set of outlet openings (8) is spaced 0.5 mm to 3 mm, more preferably 1 mm to 3 mm, from an adjacent outlet opening (8) of another set of outlet openings (8).

12. The method according to claim 1 or 2, wherein adjacent outlet openings (8) of the same set of outlet openings (8) are spaced further apart from each other by a distance greater than the distance between adjacent outlet openings (8) of different sets of outlet openings.

13. The method according to claim 1 or 2, wherein the outlet opening (8) of the carrier disk (7) or the plurality of sets of the outlet openings (8) includes 50 to 150 outlet openings (8), preferably 70 to 120 outlet openings (8), and more preferably 85 to 110 outlet openings (8).

14. The method according to claim 1 or 2, wherein the outlet opening (8) has a diameter of 0.4 mm to 3 mm, preferably 0.5 mm to 2 mm.

15. The method according to claim 1 or 2, wherein the thickness of the sheet material (70) is 0.05 mm to 1.5 mm, preferably 0.1 mm to 1 mm, and most preferably 0.2 mm to 0.8 mm.

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