Capsules and manufacturing methods for producing said capsules

Abstract

The present invention relates to a capsule having a body with a circumferential side wall extending around an interior space thereof, the interior space being filled with beverage ingredients for beverage preparation; a base wall covering the interior space at a first end of the side wall; a flange arranged circumferentially around an open face of the capsule at a second end of the side wall opposite the base wall; a lid covering the interior space and the open face of the capsule at the base wall and the second end and closing the capsule, the lid being removably attached to the flange; a filter element arranged in the interior space between the ingredients and the lid; and a carrier disc provided in the interior space between the lid and the filter, the carrier disc having a pre-formed outlet opening for discharging the beverage from the interior space to the outside when the capsule is used in a beverage preparation device, the capsule comprising a mechanical deformation at or near the junction of the flange and the side wall, the mechanical deformation holding the disc within the interior space.

Description

[[Technical Field]]

[0001] The present invention relates to a capsule integrated with a filter element for preparing a beverage, preferably a non-crema coffee, tea, milk or chocolate-based beverage.

[0002] The capsule comprises a substantially rigid capsule body having a circumferential side wall extending around an interior space of the capsule that is at least partially filled with beverage raw material for preparing a beverage such as coffee, a base wall covering the interior space at a first end of the side wall, and a lid covering the interior space at a second end of the side wall opposite the base wall. The capsule integrates a filter and an aluminum disk provided with an opening in its interior space, and the lid is removably attached to the capsule.

[0003] The present invention also relates to a process for manufacturing said capsule. [[Background Art]]

[0004] Capsules for preparing a beverage in a beverage preparation device, having 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 raw material, typically roasted and ground coffee or tea, or to prepare a beverage from soluble raw material, typically instant coffee, instant tea or instant milk, or a chocolate-based product, contained within the interior space of the capsule.

[0005] In many of the capsules currently available on the market, the interior space of the capsule is hermetically or liquid-tightly closed from the environment before being used in a beverage preparation device, in order to maintain or extend the freshness of the beverage raw material during storage.

[0006] In this regard, the capsule often comprises a substantially rigid capsule body having circumferential sidewalls extending around an internal space, and a base wall covering the internal space at a first end of the sidewalls. At a second end of the sidewall opposite the base wall, the capsule body has an open-fill side. An impermeable lid, such as an aluminum lid, is provided on the open-fill side of the capsule body to cover the internal space. When in use, the capsule may preferably be perforated in the base wall and / or lid to form an injection opening for injecting a liquid such as hot water, and / or an exit opening that allows the prepared beverage to exit the capsule.

[0007] The known capsules are more specifically designed for preparing espresso-type beverages using a beverage preparation device that delivers pressurized hot water. The injection of pressurized hot water into the capsule results in the extraction of substances from the coffee beverage raw materials, forming foam on top of the beverage, corresponding to an espresso beverage with a crema layer, as obtained with known piston-type espresso machines that use high-pressure brewing.

[0008] For coffee beverages without crema, such as filter coffee, a specific apparatus is typically used in which the beverage is prepared by non-pressurized filtration of a mixture of beverage ingredients and water.

[0009] Several capsules have been proposed for use in pressurized beverage devices to prepare coffee without crema.

[0010] European Patent No. 2952125(A1) discloses a capsule for preparing a beverage using an extractable product contained within the internal space of the capsule. 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 outermost boundary of the capsule in the axial direction of the capsule and includes a woven or nonwoven filter material such as filter paper.

[0011] International Publication No. 2019 / 013623(A1) proposes a capsule comprising a rigid capsule body having circumferential and base walls that define an internal space filled with beverage raw materials. The opening-filling side of the capsule at the end of the circumferential wall opposite the base wall is covered with a lid made of liquid-tight material. The lid has a pre-formed outlet opening suitable for discharging the prepared beverage from the internal space when the capsule is used in a beverage preparation device. The outlet opening is liquid-tightly closed by a removable cover element extending over at least a portion of the lid.

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

[0013] Therefore, the proposed object of the present invention is to provide a capsule of simple structure and a corresponding manufacturing method for producing a crema-free filter coffee beverage that has all the characteristics of filter coffee made in a drip coffee machine and conforms to the expected sensory results in the cup that consumers expect. [Overview of the Initiative]

[0014] In this regard, the present invention provides a capsule for providing a crema-free coffee, tea, milk, or chocolate-based beverage as described in claim 1 and herein.

[0015] The capsule described in the claim is intended for preparing a beverage, A substantially rigid capsule body having circumferential side walls extending around an internal space of the capsule, wherein the internal space is at least partially filled with beverage raw materials suitable for preparing a beverage, A rigid base wall integrated with the capsule body, the base wall comprising a rigid base wall covering the internal space at the first end of the side wall, The capsule opening is at the second end of the side wall of the base body opposite the base wall. side A flange arranged circumferentially around it, The opening of the capsule to the interior space is at the second end of the side wall opposite the base wall. side Cover and the capsule sealing A lid which is removably attached to the flange of the capsule, A filter element is placed within the internal space of the capsule between the beverage ingredients and the lid, A carrier disc provided within the internal space of the capsule between the lid and the filter, the carrier disc having a plurality of pre-formed outlet openings suitable for discharging the prepared beverage from the internal space to the outside of the capsule when the capsule is used in a beverage preparation device, According to the present invention, the capsule has at least one mechanically deformable portion at or near the joint between the flange and the side wall of the capsule, the mechanically deformable portion holding the carrier disk within the internal space of the capsule.

[0016] In the case of a capsule containing roasted and ground coffee as a beverage ingredient, a specific structure of the capsule makes it possible to obtain coffee with limited foam and cream formation when the capsule is extracted in the beverage preparation after the lid is removed.

[0017] This freshly brewed coffee exhibits the main characteristics of a filtered coffee: it has little crema, which disappears quickly, leaving only a crown of crema around the edge of the cup. The result in this cup is a coffee that is aromatic, soft, smooth, and sweet, yet light in body, with low acidity, low bitterness, and no harshness.

[0018] Thanks to its specific structure, the carrier disc and filter are retained inside the capsule when the lid is removed for capsule extraction. Similarly, the integrity of the capsule is maintained during and after extraction (when the lid is removed) in the beverage preparation machine, and no coffee (moist coffee) powder leaks out of the capsule.

[0019] Thanks to the proposed invention, in the capsule described in the claims, the carrier disc is positioned inside the capsule and kept at a distance of 0.1 mm to 2 mm from the lid. This avoids potential interactions between the carrier disc and the tearing surface of the extraction plate of the beverage preparation device when the coffee bed volume expands during extraction.

[0020] In fact, the capsule should sustain an extraction process in which the beverage raw materials are extracted at a pressure of less than 8 bar, more preferably less than 5 bar.

[0021] In this proposed capsule structure, the filter element comprises a layer of nonwoven material adapted to prevent coffee drain from passing through and reduce the formation of a crema layer.

[0022] In the currently envisioned solution, the filter is placed on the carrier disk. This allows for easier handling during the capsule assembly process. Furthermore, the filter may be fixed to the carrier disk.

[0023] The capsule lid features a free-moving pull tab that protrudes from the lid. The pull tab is integrated with the lid, allowing the entire lid to be removed. This makes handling and opening easier.

[0024] In the proposed embodiment, the lid comprises at least an aluminum layer to ensure a better shelf life for the coffee within the capsule.

[0025] In addition, the lid may further comprise a plastic layer and / or a heat-sealing layer to ensure food-grade compatibility for sealing the lid onto the flange of the capsule.

[0026] Preferably, the carrier disk is made of aluminum, which enables easy recycling through conventional aluminum processing when the capsule is also made of aluminum.

[0027] Preferably, the capsule body, the lid, and the carrier disk are each mainly made of aluminum. The use of aluminum ensures better protection of coffee and a longer shelf life. Furthermore, end-of-life processing and recycling of the capsule are easier.

[0028] In an alternative method, the capsule body, the lid, and the carrier disk may each be made of plastic, or laminated or multi-layer plastic elements.

[0029] The proposed capsule contains a beverage raw material. The beverage raw material is ground coffee in an amount of preferably at least 4 g, more preferably 4.5 g to 15 g.

[0030] In the proposed embodiment of the present invention, the at least one mechanically deformed portion is provided at the opening of the capsule on a side opposite to the base wall, at or near the junction between the flange and the side wall of the capsule side .

[0031] In another proposed embodiment of the present invention, the at least one mechanically deformed portion is provided at the opening of the capsule on a side opposite to the opening, at or near the junction between the flange and the side wall of the capsule side beside . ​

[0032] According to the present invention, at least one mechanically deformed portion at the joint between the flange and the side wall of the capsule is deformation due to crimping. (Capsule opening) side This crimp deformation, which reduces the diameter of the opening, allows the carrier disk to be held inside the capsule by deforming the capsule (made of ductile material).

[0033] To provide sufficient and efficient retention of the carrier disk within the capsule, the number of mechanically deformable points, also known as crimp points, is between 2 and 10.

[0034] The mechanically deformed portion is angularly distributed at the joint between the flange and the side wall of the capsule, and preferably, the mechanically deformed portion is evenly distributed at the joint between the flange and the side wall of the capsule.

[0035] The mechanically deformable portion has a rounded crimped imprint (or shape) to avoid the formation of holes in the aluminum layer of the capsule.

[0036] The present invention further provides a method for producing capsules suitable for preparing the beverage described in the claims.

[0037] The proposed manufacturing method is, A circumferential side wall extending around an internal space that is at least partially filled with beverage ingredients suitable for preparing a beverage, a rigid base wall integral with the capsule body, the base wall covering the internal space at a first end of the circumferential wall, and the opening of the capsule at a second end of the side wall of the base body opposite the base wall. side The steps include: preparing a substantially rigid capsule body having flanges arranged circumferentially around it; The opening of the capsule body on the opposite side of the base wall. side The process involves filling the internal space with a certain amount of beverage raw materials, After filling the internal space with beverage ingredients, the capsule body is opened. side The steps include inserting a filter into the internal space through the filter, Opening of the capsule body side A step of inserting a carrier disc onto a filter in an internal space through a device, wherein optionally, the filter and carrier disc are inserted simultaneously into the internal space of the capsule, and the carrier disc has multiple outlet openings from which a beverage prepared at the time of use can flow out of the capsule. Equipped with a pull tab, opening side By attaching the lid extending above to the flange of the capsule flange, the opening of the capsule is created. side The step of closing the lid, the lid is closed sealing It includes the steps to do so.

[0038] According to the present invention, the manufacturing method further includes the step of mechanically deforming the capsule at or near the joint between the flange and the side wall of the capsule, such that the mechanically deformed portion holds the carrier disc within the internal space of the capsule.

[0039] The proposed manufacturing process requires no major changes other than inserting a new machine or module for inserting filters and carrier discs and crimping capsules, and can be easily implemented on existing capsule manufacturing lines.

[0040] The step of mechanically deforming the capsule at the joint between the flange and the side wall is the opening of the capsule. side This step is performed before closing the lid. This process eliminates the risk of puncturing the lid during crimping, and ensures that the product remains perfectly sealed once the lid is assembled.

[0041] In an alternative embodiment, the step of mechanically deforming the capsule at the joint between the flange and the side wall is the opening of the capsule. side This is done after the step of closing it with a lid.

[0042] The step of mechanically deforming the capsule at the joint between the flange and the side wall is performed on the opposite side of the base wall, at the opening of the capsule. side It will be held at [location].

[0043] In an alternative embodiment, the step of mechanically deforming the capsule at the joint between the flange and the side wall is the opening of the capsule. side and opposite opposite side It will be executed.

[0044] The step of mechanically deforming the capsule at the joint between the flange and the side wall is performed using a crimping method. The advantage of this method is that the side wall is deformed without the formation of an opening / perforation area.

[0045] The step of mechanically deforming the capsule at the joint between the flange and the side wall is performed using at least one crimp pin.

[0046] At least one crimping pin has a rounded end shape to avoid puncturing the side wall of the capsule. According to the present invention, during the step of mechanically deforming the capsule at the joint between the capsule flange and the side wall, the capsule is deformed at at least two points, preferably three to ten points. A solution having eight crimping points was tested and validated as a balance between truly good fixation of the disc and the ease with which crimping tools can be manufactured.

[0047] The mechanically deformed portion is angularly distributed at the joint between the capsule flange and the side wall, and preferably evenly distributed. To equally distribute the holding force, it is advantageous to evenly cover the entire disk surface. This provides the best possible fixing effect for the disk within the capsule.

[0048] Specific embodiments of the present invention are described in the following detailed description. These objectives are achieved by the present invention, namely the capsule, system, and capsule manufacturing method.

[0049] The present invention will be further described with reference to the following embodiments and drawings, which form part of the present invention. Unless otherwise clearly and expressly indicated, the drawings do not reflect any limitation of the scope of the present invention in any sense. It will be understood that the present invention as described in the claims is not intended to be limited in any form by these embodiments and drawings.

[0050] Please note that the figures are merely schematic diagrams of embodiments of the present invention given as non-limiting examples. [Brief explanation of the drawing]

[0051] Next, embodiments of the present invention will be described as examples with reference to the attached drawings. [Figure 1a] This is a perspective side view of a sealed capsule before use in a beverage preparation device according to the present invention. [Figure 1b] This is a perspective side view of a capsule with the lid partially removed, according to the present invention. [Figure 1c] This is a perspective side view of a capsule according to the present invention, with the lid removed and ready for use in a beverage preparation device. [Figure 2a] This is a schematic cross-sectional view of a capsule according to a first embodiment of the present invention. [Figure 2b] Figure 2a is a magnified view of the identified bottom of the capsule. [Figure 2c] This is a diagram of the capsule carrier disk in Figure 2a before it is assembled inside the capsule. [Figure 3a] This is a schematic cross-sectional view of a capsule according to a second embodiment of the present invention. [Figure 3b] Figure 3a is a magnified view of the identified bottom of the capsule. [Figure 4a] This is a schematic diagram of the capsule carrier disk of Figure 2a after it has been assembled within the capsule having four crimp points, according to the first proposed embodiment. [Figure 4b]Figure 2a is a schematic diagram of the capsule carrier disk after it has been assembled within the capsule having eight crimp points, according to the first proposed embodiment. [Figure 5a] This is a schematic diagram of the proposed process for assembling a carrier disk within a capsule according to the first and second proposed embodiments. [Figure 5b] This is a schematic diagram of the proposed process for assembling a carrier disk within a capsule according to the first and second proposed embodiments. [Figure 6a] This is an enlarged view of the identified bottom of the capsule according to a third embodiment of the present invention. [Figure 6b] This is a schematic diagram of the proposed process for assembling a carrier disk within a capsule according to the third proposed embodiment. [Figure 7] This is a schematic diagram of the proposed process for assembling a carrier disk within a capsule, according to an additional proposed embodiment. [Modes for carrying out the invention]

[0052] When used herein, the terms “equipped,” “equipped,” and similar terms should not be interpreted as exclusive or exhaustive. In other words, they are intended to mean “included” but “not limited.”

[0053] No reference in this specification to prior art documents should be considered to acknowledge that such prior art is well known or that it forms part of the common general knowledge in the art.

[0054] Figure 1a shows a capsule 1 according to the present invention before use in a beverage preparation device, as defined in its storage state. Using reference to Figure 2, the capsule 1 in Figure 1a comprises a rigid capsule body 2. The body 2 comprises a frustoconical side wall 2a extending circumferentially around the internal space of the body. The capsule further comprises a base wall 3 integral with the capsule body 2, which closes the internal 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 side wall 2a of the capsule body. At the second end of the side wall, the capsule body 2 has an open-fill side.

[0055] As usual, the capsule body 2 is processed to be food-grade and, in most cases, includes a lacquer layer or polymer film layer (identified as 2b in Figure 9b) applied to the inside of the capsule body.

[0056] The capsule further includes a lid 5 that is attached to a flange 4 on the capsule body and thereby seals the capsule. The lid 5 may be manually removed from the capsule by pulling a pull tab 6. In this case, the pull tab 6 is integrated with the lid 5, but alternative solutions are available.

[0057] The lid 5 is a flexible sheet-like foil made of aluminum, having an optional lacquer layer or polymer layer on the sealing side.

[0058] 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 its sealing side, the thickness of the polymer layer may be 0.01 mm to 0.05 mm.

[0059] 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 be, for example, a heat-seal lacquer layer or a polymer film layer.

[0060] For example, the sealing layer forming the adhesive material may be a layer of 0.003 mm to 0.03 mm thickness.

[0061] The layer of adhesive material allows the lid 5 to be removed from the flange 4 of the capsule without damaging the capsule 1.

[0062] The internal space of the capsule is filled with beverage ingredients before the capsule is closed. In this case, the capsule is sealed with a lid 5 to maintain the freshness of the roasted and ground coffee. sealing The capsules are filled with coffee grounds that have been roasted and ground before being used. The weight of the coffee ranges from 4g to 15g depending on the size of the capsule. However, tea, milk, or chocolate ingredients may be used instead.

[0063] The capsule in Figure 1b shows the capsule from Figure 1a with the lid 5 partially removed by tearing the pull tab 6, and Figure 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 and shows a membrane on the inside of the capsule, which is defined as the carrier disc 7. The carrier disc 7 has a number of pre-formed outlet openings 8 for the beverage (here, coffee) to be prepared in the beverage preparation device. The capsule also has mechanical deformations 11a, 11b, 11c... that occur at the joint between the side wall 2a and the flange 4, holding the carrier disc 7 within the internal space of the capsule. Four mechanical deformations 11 are seen in Figure 1b. These mechanical deformations 11a, 11b, 11c... are also seen on the capsule in Figure 1c, and in fact eight mechanical deformations can be observed. Their function and how they are performed will be described in relation to Figure 2a and below.

[0064] The pre-formed exit 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 internal space of the capsule to ensure the freshness of the beverage ingredients inside the capsule during storage.

[0065] As can be seen in the cross-sectional views of various embodiments of the capsule of the present invention (see, for example, Figure 2a), the capsule further comprises a filter element 9 positioned between the coffee bed and the carrier disc 7 within the internal space of the capsule. The filter element 9 prevents solid particles of the beverage raw materials, such as coffee particles or tea leaves, from flowing out of the capsule into the final consumer cup during extraction.

[0066] In the proposed invention, the capsule body 2 and the lid 5 are each made primarily from aluminum.

[0067] However, other materials may be considered for the capsule body and lid.

[0068] 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.

[0069] As is understood, the capsules of the present invention are extracted using a conventional high-pressure beverage preparation device compatible with conventional Nespresso® coffee capsules. The beverage preparation device comprises a fluid distribution device capable of supplying a certain amount of fluid, such as water, to the capsule at a pressure of 0.1 to 20 bar, and a brewing chamber having a first portion for holding the capsule and a second portion for closing the brewing chamber, the second portion of the brewing chamber comprising an extraction plate having a tearing surface for engaging with the capsule at the second end opposite the base wall of the capsule.

[0070] To summarize the conventional extraction process of a closed capsule in a beverage preparation device, the capsule is inserted into the brewing chamber of the beverage preparation device. A fluid distribution device supplies a fluid, such as water, in a given amount through the base wall 3 inside the capsule to steep and then extract the coffee. As the pressure inside the capsule increases, the lid of the capsule comes into contact with the tearing surface of the extraction plate, and the lid is modified by this tearing surface, leading to the formation of an opening from which the coffee can flow out of the capsule.

[0071] The interaction between the lid and the tearing surface, which creates an outlet opening on the lid's surface to allow the coffee to flow out, is involved in the formation of foam and cream during the preparation process.

[0072] Using conventional capsules (closed capsules) in conjunction with the process described above leads to coffee extraction at pressures of 8 to 20 bar.

[0073] In the capsule extraction process of the present invention, the capsule lid is removed before inserting the capsule into the brewing chamber of the beverage preparation device. A fluid distribution device supplies a fluid, such as water, in an amount present in the capsule through the base wall 3 inside the capsule to steep and then extract the coffee. The extracted coffee passes through the filter element 9 and then flows out through the outlet opening of the carrier disc 7. During extraction, the carrier disc 7 (located at a certain distance from the flange of the capsule) does not come into contact with the tearing surface of the extraction plate of the beverage preparation device, so the carrier disc 7 is not altered by tearing during capsule extraction.

[0074] The use of the capsule of the present invention (in conventional beverage preparation devices) leads to coffee extraction at a pressure of 0.1 bar to 8 bar, depending on the amount of coffee in the capsule and the filter element structure.

[0075] Due to the fact that the lid is removed from the capsule before use in the beverage preparation device and the carrier disc is placed inside the capsule (see, for example, Figure 2a), there is no interaction between the carrier disc 7 and the tearing surface of the extraction plate.

[0076] More specifically, when preparing coffee using the capsule 1 of the present invention in a beverage preparation device, the user removes the lid 5 by tearing off the pull tab 6 before inserting the capsule into the beverage preparation machine. The base wall 3 of the capsule body 2 is further perforated and opened by the perforating means of the beverage preparation device for supplying water into the capsule under pressure for the preparation of the coffee beverage.

[0077] 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 rising extraction pressure within the capsule (0.1 to 6 bar), thereby limiting the formation of foam and cream during extraction.

[0078] Therefore, in the interaction between the coffee / lid / opening element(s) and the tearing surface of the extraction plate of the beverage preparation device, there is no pressure increase or rapid pressure decrease (similar to the use of conventional capsules), resulting in coffee in the cup with little to no crema.

[0079] The capsule of the present invention makes it possible to prepare coffee, tea, milk, or chocolate without crema, depending on the beverage ingredients inside the capsule.

[0080] Figure 2a shows a first embodiment of the capsule of the present invention. As disclosed, the capsule comprises a carrier disk 7 in its internal space, having a plurality of pre-formed exit openings 8.

[0081] As shown in Figure 2b, which is an enlarged cross-sectional view of the identified bottom portion of Figure 2a, the carrier disc 7 is positioned inside the capsule at a distance of 0.1 mm to 2 mm from the lid 5, and the lid 5 is sealed on the flange 4.

[0082] This gap between the capsule lid 5 (and therefore the flange 4 after the lid is removed for extraction) and the carrier disc 7 provides a recess for the tearing surface of the extraction plate of the beverage preparation device to protrude into the capsule without contacting the carrier disc 7 and thus the coffee inside the capsule.

[0083] The carrier disk 7 is a substantially circular material, as shown in Figure 2c, and its diameter is approximately equal to the inner diameter of the capsule where the carrier disk 7 is positioned / inserted / maintained according to the assembly process.

[0084] Therefore, in the proposed embodiment, the diameter of the carrier disk 7 is approximately 29.5 to 30.5 mm.

[0085] In the proposed embodiment, the carrier disc is made of aluminum. Its thickness is approximately 0.3 mm, but may vary between 0.1 mm and 1 mm.

[0086] In the proposed solution, the carrier disc 7 is kept inside the capsule thanks to a localized mechanical deformation 11 created on the capsule at the joint between the side wall 2a of the capsule 1 and the flange 4. In the detailed cross-sectional view of Figure 2b, one mechanical deformation 11 is visible. The mechanical deformation is in the form of a crimp point 11, on the opposite side of the base wall 3 from the opening of the capsule. side It is located in [location].

[0087] Since the capsule is made of a ductile material, preferably aluminum, the mechanical deformation caused by the crimp reduces its diameter, thereby allowing the carrier disc 7 (and filter) to be held inside the capsule. The carrier disc is held inside the capsule 1.

[0088] Here, during the manufacturing process, before closing the capsule with the lid 5, the capsule is subjected to a step in which it is mechanically deformed at the joint between the flange 4, which leads to the crimp point 11, and the side wall 2a.

[0089] The crimp points 11 (also visible in Figure 1c), which are 2 to 10 crimp points, are located at the joint between the flange and the side wall of the capsule, and the opening of the capsule. side They are distributed angularly around it.

[0090] Considering the tools used to create the crimp point, the crimp point 11 is preferably the opening of the capsule. side They are evenly distributed around it.

[0091] In addition, the crimp point 11 may have a rounded crimp imprint depending on the crimping tool used.

[0092] Alternatively, the carrier disc 7 may be made of plastic or a laminated film containing polyolefins, such as polypropylene, polyethylene, or any other semicrystalline polymer. The carrier disc 7 may also be made of a paper-based material, such as coated paper, laminated paper, or molded paper.

[0093] As shown in Figure 2c, the pre-formed outlet openings 9 are circular openings uniformly distributed on the surface of the carrier disk. This uniform distribution of outlet openings ensures a uniform flow of coffee out of capsule 1. This also helps to avoid the formation of channels by the beverage (coffee bed) inside the capsule.

[0094] The opening has a diameter set to approximately 0.75 mm to 1 mm, but the diameter may vary between 0.4 mm and 3 mm, most preferably between 0.5 mm and 1.3 mm.

[0095] The number of pre-formed outlet openings may vary depending on the size of the capsule and how quickly the coffee needs to be dispensed. In the disclosed embodiment, the carrier disc 7 has 50 to 150, preferably about 90, and in the shown embodiment, 92 openings.

[0096] In an alternative embodiment, the pre-formed outlet opening may be elliptical in shape.

[0097] As presented, the capsule further comprises a filter element 9 which is placed on a raw material bed (e.g., coffee bed) after the capsule is filled during the possible assembly process, and a carrier disc 7 which is placed between the filter element and the lid 5.

[0098] The capsule is inverted, and the filter element 9 is positioned on the carrier disk 7, as shown in the enlarged view of Figure 2b. The filter element is then supported by the carrier disk 7 within the capsule. The filter remains flat within the capsule and does not come into contact with the tearing surface of the extraction plate of the beverage preparation device during extraction.

[0099] The use of a two-piece design may allow for the use of non-sealable filter materials, which could be an advantage for sustainability.

[0100] As proposed in this embodiment, the filter element 9 is circular (disk-shaped) with a diameter smaller than the diameter of the carrier disk 7, i.e., 28 mm to 30.5 mm, generally 0.1 mm smaller than the disk carrier.

[0101] However, in an alternative embodiment, the diameter of the filter element 9 may be similar to the diameter of the carrier disk 7.

[0102] The filter element 9 is made of a nonwoven fabric material adapted to prevent / suppress the passage of coffee drain excessively slowly or excessively quickly during beverage extraction, with the aim of avoiding the formation of a crema layer and preventing coffee drain from passing through the disc carrier and directly into the cup.

[0103] The filter is preferably made of a compostable and / or biodegradable material and may be made of a cellulose-based material having the following technical characteristics: It may be, for example, a paper-based filter element.

[0104] The filter element 9 of the proposed embodiment has a thickness of 20 to 300 microns, an air permeability in the range of 100 to 5000 l / m² / s according to ISO 9237, and a weight in the range of 5 to 600 g / m². It may be, for example, a paper-based filter element.

[0105] The filter element may include a layer of nonwoven material connected to another filtering layer by any known means.

[0106] In the proposed embodiments shown in Figures 2a and 2c, the filter element 9 and the carrier disk 7 are independent elements placed on top of each other. However, they may be assembled together, for example, by adhesive. This alters the assembly process within the capsule, as the insertion of the filter and carrier disk is performed in a single step.

[0107] The proposed circular carrier disk 7 may have a tapered shape around its circumference to fit (pressure fit) into a capsule having a frustoconical shape. However, other alternative shapes and arrangements of the carrier disk within the capsule are also possible.

[0108] In a beverage preparation machine, it is important that the carrier disc 7 and filter element 9 remain in place within the capsule when the lid 5 is removed and the capsule 1 is extracted. Several assembly processes may be considered and will be disclosed later in connection with the proposed embodiment of the capsule according to the present invention.

[0109] In a further developed solution of the first embodiment of the present invention shown in Figures 3a and 3b (details of Figure 3a), a second filter made of, for example, a nonwoven fabric material is added to the inside of the capsule. The second filter element may be positioned on a carrier disc on the side facing the lid (the side opposite the coffee that directly faces the pyramidal plate of the beverage preparation device) and fixed to the carrier disc without contacting the lid.

[0110] The purpose of this second filter 10 is to allow lateral flow of coffee when the perforations coincide with the flat top surface of the truncated pyramid.

[0111] As mentioned above, the second filter element is made of nonwoven fabric, but it can be made of any suitable element that fits the required function.

[0112] The second filter element may have the following dimensions, ranging from 28 mm to 30.5 mm:

[0113] In the proposed embodiment, the second filter element is substantially circular, having a diameter slightly smaller than that of the carrier disk 7.

[0114] The assembly process and configuration proposed in relation to Figures 2a to 2c can still be applied to this further developed solution.

[0115] Figures 4a and 4b show the opening of the capsule by inserting the carrier disk 7 into the capsule shown in Figure 2a and attaching the lid. side Before closing, the capsule as assembled inside the capsule at 4 and 8 crimp points respectively, as shown in Figure 2a (capsule opening) side This represents a view from that perspective.

[0116] The number of crimp points (mechanically deformable parts) may vary between 2 and 10 to enable the carrier disk 7 (and the filter element 9 supported by the carrier disk) to be held sufficiently and efficiently within the capsule 1.

[0117] The crimp point 11 is at the joint between the side wall 2a of the capsule and the flange 4, and is at the opening of the capsule. side They are distributed angularly around the periphery. Preferably, as presented herein, the crimp points are at the opening of the capsule. side They are evenly distributed along the periphery.

[0118] The toolwork currently used in the step of mechanically deforming the capsule has a rounded end shape that allows for crimp points having substantially rounded crimp imprints.

[0119] Figures 5a and 5b schematically illustrate how the mechanical deformation of the capsule according to Figure 2a can occur.

[0120] Figure 5a shows the capsule 1 with the carrier disk 7 inserted (in cross-section). A crimping tool (also called a clamping tool) 18 is visible, which has two crimping pins 18a, each with a rounded end shape 19. This crimping tool causes local deformation of the capsule body, thus opening the capsule. side Therefore, it is in a position where it is ready to be pressed onto the capsule at the joint between the side wall 2a and the flange 4.

[0121] Figure 5b shows the same capsule after the joint between the side wall 2a and the flange 4 has been mechanically deformed by the crimping tool 18. As can be seen, the mechanical deformation on the capsule at this particular location induces crimp points 11 and generates beads 20 for each mechanical deformation (due to the physical movement of the material).

[0122] Since the beverage ingredients, filter element 9, and carrier disc 7 should remain inside the capsule during the mechanical deformation step of the capsule, this step is necessary for the capsule to open. side This is done while it is positioned facing upwards.

[0123] In this configuration, the formed bead 20 (which can also be called a burr) is located above the carrier disk 7.

[0124] Considering the capsules in Figures 2a and 2b, the bead 20 is located beneath the carrier disk 7, thus allowing the carrier disk 7 to be held within the capsule.

[0125] Depending on the number of crimping points 11 performed on the capsule, the crimping tool 18 is equipped with 2 to 10 crimping pins 18a. Thus, the crimping tool has angularly distributed crimping pins 18a.

[0126] In Figures 5a and 5b, the sealing means 21 are located on the capsule. These sealing means provide a fluid sealing engagement with the sealing profile of the capsule engaging member of a beverage preparation machine, as disclosed, for example, in European Patent No. 1654966(B1).

[0127] As is clear from the figure, the sealing means 21 is not damaged during the mechanical deformation of the capsule, and the sealing function provided by the sealing means is maintained.

[0128] For example, as disclosed in European Patent No. 2303077(B1) or No. 2387922(B1), the sealing function of a sealing means created by projections on the flange of a capsule and / or deformation of the flange is maintained thanks to the specific position of the mechanically deformed portion.

[0129] To better understand the complete manufacturing process, the steps of this process leading to the capsule are shown below, as illustrated in Figure 2a.

[0130] First, a substantially rigid capsule body 2 is provided, having circumferential side walls 2a extending around an internal space that is at least partially filled with beverage raw materials suitable for preparing a beverage. The manufacture of this capsule body can be carried out by deep drawing of aluminum foil, but other techniques exist depending on the material of the capsule body.

[0131] As mentioned above, the capsule body 2 consists of a side wall 2a, a bottom wall 3, and an opening in the capsule on the opposite side of the bottom wall. side It comprises a flange 4 in the and

[0132] Next, the interior space is the opening of the capsule. side It is filled with a certain amount of beverage ingredients. The amount of beverage ingredients depends on the type of beverage, such as coffee or tea, but also on the type of beverage being served (such as lungo).

[0133] Once the capsule is filled with beverage ingredients, the filter element 9 opens the capsule body. sideIt is inserted into the internal space through this. Therefore, the configuration in Figure 5a (capsule opening) side (With the filter facing upwards), the filter element is inserted into the capsule at the top of the beverage ingredients.

[0134] Next, the carrier disc 7 is inserted into the opening of the capsule body. side It is inserted over the filter element 9 in the internal space through this.

[0135] As already detailed, the carrier disc 7 is equipped with multiple outlet openings 8 from which the beverage prepared during use can flow out of the capsule. Optionally, the filter element 9 and the carrier disk 7 may be inserted into the internal space of the capsule simultaneously. Both elements may or may not be attached together when inserted together.

[0136] Next, as previously described, a step is taken to mechanically deform (also defined as crimping) the capsule at or near the joint between the flange and the side wall in order to provide the carrier disc to be held within the internal space of the capsule. The crimping may be performed simultaneously at several points, or at 2 to 10 crimping points by the specific crimping tool 18 disclosed above. Preferably, the crimping points are at the joint between the flange and the side wall of the capsule, and at the opening of the capsule. side They are evenly distributed along the periphery.

[0137] Capsule opening side The opening is further closed by attaching lid 5. Depending on the material of the lid, various techniques may be used. In the case of aluminum leads (including laker), heat sealing may be used.

[0138] According to the proposed capsule, the lid 5 is equipped with a pull tab 6.

[0139] The lid that seals the capsule may be removed from the capsule before use in the beverage preparation device. Next, the capsules are removed from the production line and ready for use.

[0140] It should be noted that the sealing means 21 are not damaged during the crimping step, and therefore their associated sealing function is fully maintained.

[0141] In the above disclosure, the step of mechanically deforming the capsule is the opening of the capsule. side The deformation step is performed before the step of closing the lid, but the capsule opening side This is likely to be done after closing the lid.

[0142] As shown in Figures 6a and 6b, at least one localized mechanical deformation aimed at maintaining the carrier disk 7 inside the capsule body prevents the capsule from opening. side and the opposite side The deformation is then performed at the edge of the flange, that is, at the joint between the side wall 2a and the flange 4. Here, the mechanical deformation is applied directly to the side surface of the side wall 2a of the capsule body 2.

[0143] Similarly, as described in Figures 5a and 5b, a crimping tool 18 having at least one crimping pin 18a is used to provide a mechanically deformable portion at a specific location in the capsule in order to hold the carrier disk 7 inside the capsule.

[0144] This modification can be performed before or after the lid 5 is placed on and / or sealed in the capsule. When this modification is used, the distance between the carrier disc 7 and the flange of the capsule body is smaller than the distance when local deformation occurs on the side wall of the capsule body (but still sufficient to avoid interaction between the carrier disc and the location of the pyramidal part of the beverage device during extraction) (Figure 6b).

[0145] Figure 7 illustrates the mechanical deformation of the capsule during the assembly process, in which the capsule's carrier disk 7 is clamped inside the capsule body due to local deformation of the capsule from the outside.

[0146] In the assembly process shown in Figure 7, when the carrier disc 7 (or the carrier disc 7 and filter element 9) is inserted into the capsule body 7, the crimping tool 18 presses against the capsule body from the outside, near the joint between the flange and the side wall of the capsule, just above the level of the carrier disc 7 when it is positioned within the internal space of the capsule, causing a local deformation 11 of the capsule body. Thanks to this local deformation, the carrier disc 7 is maintained in place within the capsule.

[0147] Local deformation of the outer surface of the capsule body from the outside occurs along its circumference, for example, every 90°. This is sufficient to ensure efficient retention of the carrier disk 7.

[0148] As presented, the step of locally mechanically deforming the capsule at the joint between the flange and the side wall is performed using a crimping method, but other methods for mechanically deforming the capsule at this particular location, such as stamping, metal drawing, or embossing, may also be used.

[0149] To improve the retention of the carrier disk 7 (with or without the filter element 9) within the capsule body 2, the shown embodiments for the carrier disk and the manufacturing and assembly processes can be combined whenever necessary and possible.

[0150] The shown capsule may be associated with sealing means located on the flange of the capsule to ensure liquid-tightness between the capsule and the dispensing section of the beverage manufacturing machine. For example, the sealing means may be a silicone ring applied to the base of the flange and the side wall of the capsule body, or one or more projections or bridges formed on (and integrated with) the flange. Such sealing means (not shown) are involved in the liquid-tightness with the beverage manufacturing machine.

[0151] While the present invention has been described using examples, it should be understood that modifications and alterations can be made without departing from the scope of the invention as defined in the claims. Furthermore, where known equivalents exist for certain features, such equivalents are incorporated as if they were specifically referred to herein.

Claims

1. A capsule for preparing a beverage, A capsule body having circumferential side walls extending around the internal space of the capsule, wherein the internal space is at least partially filled with beverage raw materials suitable for preparing the beverage, At the first end of the circumferential side wall, a base wall covers the internal space, A flange is provided at the second end of the circumferential side wall of the capsule body opposite to the base wall, with the flange positioned circumferentially around the opening side of the capsule. A lid that covers the internal space and the opening side of the capsule at the second end of the circumferential side wall opposite to the base wall, and seals the capsule, the lid being removably attached to the flange of the capsule, A filter element is disposed within the internal space of the capsule between the beverage raw materials and the lid, A capsule comprising: a carrier disc provided in the internal space of the capsule between the lid and the filter element, the carrier disc having a plurality of pre-formed outlet openings suitable for discharging the prepared beverage from the internal space to the outside of the capsule when the capsule is used in a beverage preparation device, The capsule is characterized in that it has at least one mechanically deformable portion at the joint between the flange and the circumferential side wall of the capsule, and the mechanically deformable portion holds the carrier disk within the internal space of the capsule. Capsules for preparing beverages.

2. A capsule for preparing a beverage according to claim 1, wherein the at least one mechanically deformed portion at the joint between the flange and the circumferential side wall of the capsule is located on the opening side of the capsule, opposite to the base wall.

3. A capsule for preparing a beverage according to claim 1 or 2, wherein the at least one mechanically deformed portion at the joint between the flange and the circumferential side wall of the capsule is a crimp point.

4. A capsule for preparing a beverage according to any one of claims 1 to 3, wherein the number of mechanically deformable parts is at least two.

5. A capsule for preparing a beverage according to any one of claims 1 to 4, wherein the mechanically deformed portion is angularly distributed at the joint between the flange and the circumferential side wall of the capsule.

6. The capsule for preparing a beverage according to claim 5, wherein the mechanically deformed portion is evenly distributed at the joint between the flange and the circumferential side wall of the capsule.

7. A capsule for preparing a beverage according to any one of claims 1 to 6, wherein the mechanically deformable portion has a rounded crimped imprint.

8. A capsule for preparing a beverage according to any one of claims 1 to 7, wherein the capsule body, the lid, and the carrier disc are each made from an aluminum-containing material.

9. A capsule for preparing a beverage according to any one of claims 1 to 8, wherein the lid is provided with a pull tab protruding from the lid.

10. A method for producing capsules suitable for preparing beverages, wherein the method is A step of preparing a capsule body, wherein the capsule body has a circumferential side wall extending around an internal space that is at least partially filled with beverage raw materials suitable for preparing the beverage; a base wall covering the internal space at a first end of the circumferential side wall; and a flange circumferentially positioned around the opening side of the capsule at a second end of the circumferential side wall of the capsule body opposite to the base wall. The steps include filling the internal space with a certain amount of beverage raw material through the opening side of the capsule body opposite to the base wall, After filling the internal space with the beverage raw materials, the step of inserting a filter into the internal space through the opening side of the capsule body, A step of inserting a carrier disc onto the filter in the internal space through the opening side of the capsule body, wherein optionally, the filter and the carrier disc are inserted simultaneously into the internal space of the capsule, and the carrier disc has a plurality of outlet openings from which the beverage prepared at the time of use can flow out of the capsule. A method comprising the steps of: closing the opening side of the capsule by attaching a lid, which has a pull tab and extends over the opening side, to the flange, wherein the lid seals the capsule; The manufacturing method further includes a step of mechanically deforming the capsule at the joint between the flange and the circumferential side wall of the capsule, wherein the mechanically deformed portion holds the carrier disk within the internal space of the capsule. A method for manufacturing capsules.

11. A method for manufacturing a capsule according to claim 10, wherein the step of mechanically deforming the capsule at the joint between the flange and the circumferential side wall is performed before the step of closing the opening side of the capsule with a lid.

12. A method for manufacturing a capsule according to claim 10, wherein the step of mechanically deforming the capsule at the joint between the flange and the circumferential side wall is performed after the step of closing the opening side of the capsule with a lid.

13. A method for manufacturing a capsule according to any one of claims 10 to 12, wherein the step of mechanically deforming the capsule at the joint between the flange and the circumferential side wall is performed on the opening side of the capsule, opposite to the base wall.

14. A method for manufacturing a capsule according to any one of claims 10 to 13, wherein the step of mechanically deforming the capsule at the joint between the flange and the circumferential side wall is performed using a crimping method.

15. A method for manufacturing a capsule according to any one of claims 10 to 14, wherein the step of mechanically deforming the capsule at the joint between the flange and the circumferential side wall is performed using at least one crimp pin.

16. A method for manufacturing a capsule according to claim 15, wherein at least one of the crimp pins has a rounded end shape.

17. A method for manufacturing a capsule according to any one of claims 10 to 16, wherein during the step of mechanically deforming the capsule at the joint between the flange and the circumferential side wall of the capsule, the capsule is deformed at at least two points.

18. A method for manufacturing a capsule according to claim 17, wherein the mechanically deformed portion is angularly distributed at the joint between the flange and the circumferential side wall of the capsule.

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