Compostable capsule for preparing beverages

Abstract

The compostable capsule (1) for preparing a beverage in accordance with the present invention comprises: a cup (2) which is a single body made of cellulose; a cover (6); an inner sealing disc (5). An insert (3) is housed in the cup (2), the insert being a single body made of compostable plastic, and is provided with a cylindrical portion (32) ending in an outlet opening (34) for the beverage. Preferably, the outlet opening (34) of the insert (3) protrudes from the lower opening (25) of the cup (2). Advantageously, the insert is completely housed inside the cup, thus remaining correctly and firmly in position for the entire duration of the extraction. Furthermore, the compostable plastic insert is the element of the capsule which collects therein the main functional elements which require very complex geometries and extremely small dimensions.

Description

"COMPOSTABLE CAPSULE FOR PREPARING BEVERAGES"DESCRIPTION

[0001] The subject matter of the present invention is a compostable capsule for preparing beverages, provided with a cellulose body and a compostable plastic insert.

[0002] Capsules are known in the art for packaging concentrated products (in the form of soluble or insoluble powders) in pre-established and single-use doses, for the extemporaneous preparation of beverages (such as coffee, cappuccino, milk, chocolate) by means of the introduction, inside the capsule itself, of a pressurised fluid, i.e., hot water. The crossing of the food powder contained inside the capsule by the flow of hot water, dispensed by an extraction machine, determines the extemporaneous preparation of the beverage.

[0003] Different types of automatic or semi-automatic machines for preparing beverages are known in the art. One type of extraction involves piercing the capsule at the bottom of the cup-shaped body to allow the injection of pressurised hot water, and tearing the cover against piercing means of the extraction machine to allow the beverage to exit.

[0004] On the other hand, the type of capsule which is the subject matter of the present invention is very different, suitable for use in a machine which envisagespiercing the capsule only on one side , to al low the inj ection of pressurised hot water inside the cup-shaped body . The capsule which is the subj ect matter of the present invention is in fact of a complex type , comprising a cup-shaped body with a duct provided with a beverage outlet opening, a closing cover fixed to the cup-shaped body, as well as inner opening means thereof integral with the cup-shaped body . Such opening means are activated by the increase in pressure inside the cupshaped body to allow the opening of an inner sealing disc and thus allow the beverage to exit from the outlet duct present on the bottom of the cup-shaped body .

[0005] With a view to increasing attention to environmental protection, the disposal of the capsules at the end of use takes on particular importance . In particular, more and more attention is paid to compostable materials , and the need to have disposable capsules which can be directly disposed of in the compostable bin, even at home , is particularly felt . Therefore , cellulose capsules are known in the art .

[0006] Typically, for making and di spensing the beverage , the flow of hot water is inj ected inside the capsule with a pressure which can reach 15 atmospheres for a time ranging from 15 to 90 seconds . It is therefore important to select a material for the capsule which provides thenecessary features to resist the mechanical stresses , in particular the pressure , and the thermal stresses to which the capsule is subj ected during use .

[0007] The main problem with the state-of-the-art capsules lies precisely in the material with which they are made , since cellulose is poorly resistant to the thermal and mechanical stresses typical of the art of machines for preparing beverages . Furthermore, cellulose is a material with which it is very di f ficult to obtain precise geometries and complex profiles .

[0008] The obj ect of the present invention is to make a capsule for preparing beverages which solves the problems of the prior art taking into account the needs of the field .

[0009] In particular, the obj ect of the present invention is to provide a compostable capsule for preparing beverages capable of withstanding the temperatures and pressures of the machines for preparing beverages , ensuring an optimal opening and dispensing of the beverage .

[0010] Such an obj ect is achieved by a compostable capsule for preparing beverages provided with a cellulose body and a compostable plastic insert .

[0011] The features and advantages of a capsule for preparing beverages according to the present inventionwill be apparent from the description given below by way of non-limiting example in accordance with the accompanying figures , in which :- Figure 1 shows a sectional view of the capsule which is the subj ect matter of the present invention;- Figure 2 shows a view from below of a capsule which is the subj ect matter of the present invention;- Figure 3A shows a sectional view of the body and insert of the capsule which is the subj ect matter of the present invention, in a first embodiment example ;- Figure 3B shows a sectional view of the lower part of a capsule having the body and the insert of Figure 3A;- Figure 4A shows a sectional view of the body and insert of the capsule which is the subj ect matter of the present invention, in a second embodiment example ;- Figure 4B shows a sectional view of the lower part of a capsule having the body and the insert of Figure 4A;- Figure 5A shows a sectional view of the body and insert of the capsule which is the subj ect matter of the present invention, in a third embodiment example ;- Figure 4B shows a sectional view of the lower part of a capsule having the body and the insert of Figure 5A;Figure 6 shows a view of the lower portion of the capsule insert which is the subj ect matter of the present invention;- Figures 7a and 7b show an axonometric view from above of the upper portion of the capsule insert, in two further embodiment variants.

[0012] With reference to the appended figures, the reference number 1 denotes a capsule for preparing beverages, wherein the beverage (such as coffee, cappuccino, milk, chocolate) is obtained from a food substance in powder or granules, of the soluble or insoluble type.

[0013] The capsule 1 comprises a cup-shaped body 2, hereinafter simply cup 2, adapted to define an inner volume V in which at least one food substance S is contained .

[0014] The cup 2 is a cup-shaped structure, which is slightly f rustoconical .

[0015] The cup 2 comprises an upper edge 22, externally protruding said flange, which surrounds an inlet opening 20 sealingly closed by a cover 6 fixed to the upper edge 22 itself.

[0016] The cup 2 comprises, below the upper edge 22, a f rustoconical side wall 21, followed by at least one step portion 23, preferably by a consecutive pair of step portions 23, and ends with a lower portion 24, substantially funnel-shaped, defining a lower opening 25.

[0017] During the present description, the bottom 9 of thecup is identi fied with the only lower funnel portion 24 .

[0018] The cup 2 is a single body, made of compostable material . In particular, the cup 2 is made of cellulose , otherwise called cellulose pulp .

[0019] The cup 2 is made of moulded cellulose pulp . The cellulose is obtained from vegetable fibres or from recycled paper .

[0020] The cup 2 is provided with an inner surface , intended to come into contact with a liquid, which is impermeable to liquids .

[0021] In a preferred example , the cup 2 comprises an inner lining 4 made of compostable material impermeable to liquids .

[0022] Preferably, the cup 2 comprises an inner lining 4 made of compostable plastic material . Such a solution improves the fixing, by welding, of a compostable plastic insert 3 which will be discussed below .

[0023] Preferably, the inner lining 4 is a layer of polylactic acid ( PLA) . Preferably, the inner lining 4 covers the entire inner surface of the cup 2 .

[0024] In a further embodiment , the cup 2 is made of cellulose pulp with the addition of at least one compostable additive or is made of cellulose with a treatment which makes at least the inner surface of the cup 2 impermeable .

[0025] The capsule 1 comprises an insert 3, housed inside the cup 2.

[0026] The insert 3 is a single body, made of compostable plastic material. Preferably, the insert 3 is made of PLA (polylactic acid) or compounds thereof, or of PHA (polyhydroxyalkanoates) or compounds thereof. The term compound means the material obtained by mixing the basic plastic material with additives, for example light and heat stabilizers, flame retardants, antioxidants, fillers, pigments and dyes, glidants and anti-slip agents, plasticizers etc.

[0027] The insert 3 comprises a discoidal portion 31 below which a cylindrical portion 32 protrudes, at a central zone. Outflow openings 341 are made between the discoidal portion 31 and the cylindrical portion 32. The outflow openings 341 are obtained directly in the step of moulding the insert 3 (for example in Figure 7a and 7b) , or are made by shearing after the step of moulding the insert (for example in Figure 3A) or by cutting and bending after the step of moulding the insert (Figure 3B) .

[0028] The cylindrical portion defines a duct 321, said nozzle, ending in an outlet opening 34 for the exit of the beverage from the capsule 1. Therefore advantageously, the beverage flows through the outflowopenings 341 , is conveyed inside the duct 321 , and exits the capsule through the outlet opening 34 of the insert 3 .

[0029] Advantageously, as seen from the appended figures , when the insert 3 is housed inside the cup 2 , the duct 321 extends through the lower opening 25 . Preferably, only the duct 321 extends through the lower opening 25 . Preferably, the duct 321 protrudes from the lower opening 25 , i . e . , it extends through and beyond the lower opening 25 on the bottom 9 of the cup 2 .

[0030] In an embodiment example , the insert 3 is completely housed inside the cup 2 . In a further embodiment example , the insert 3 is completely housed inside the cup 2 with the exception of only the duct 321 ending in the outlet opening 34 through which the beverage flows out . Such a solution allows to correctly and firmly hold the insert 3 in position inside the cup 3 during the beverage extraction step ( step characteri zed by high pressure and temperature ) , even i f the insert 3 is not fixed to the cup 2 but is only resting at the bottom 9 of the cup 2 , as in the example of Figure 3B . Instead in the examples of Figure 4B and 5B, the insert 3 is fixed to the bottom 9 of the cup 2 , for example by welding, preferably at a step portion of both the cup and the insert .

[0031] In the capsule which is the subj ect matter of the present invention, the outlet opening 34 for the beverage is made in the compostable plastic insert 3 , and not in the cellulose cup 2 which is sensitive to high extraction pressures and temperatures . Such a solution ensures an optimal dispensing of the beverage .

[0032] Advantageously, the insert 3 comprises , protruding below the discoidal portion 31 , a plurality of fins 33 uni formly distributed along the circumference . As seen in Figure 6 , the fins 33 extend starting from the lower surface of the discoidal portion 31 until reaching the cylindrical portion 32 . Such fins 33 contribute to correctly holding the insert 3 in position inside the cup 2 . Such fins 33 also allow to uni formly discharge the pressure of the beverage extraction step directly on the bottom of the extraction chamber of the machine , avoiding unwanted deformations of the insert 3 or o f the cup 2 .

[0033] As anticipated above , while the duct 321 protrudes from the opening 25 on the bottom 9 of the cup 2 , the discoidal portion 31 is housed inside the bottom 9 of the cup 2 , and therefore the lower ( funnel ) portion 24 of the cup 2 , as seen in Figure 3B .

[0034] The discoidal portion 31 comprises a f rustoconical annular support portion 37 ( also visible in Figure 6 ) , adapted to abut against the lower portion 24 of the cup2 , as seen in Figure 3B . Such an annular support portion 37 contributes to correctly holding the insert 3 in position inside the cup 2 and to uniformly discharging the pressure of the beverage extraction step directly on the bottom of the extraction chamber of the machine , avoiding unwanted deformations of the insert 3 or of the cup 2 .

[0035] In the example of Figure 3B, the discoidal portion 31 of the insert 3 ends with a raised wall 36 , which is positioned abutting against the elevation of a step portion 23 of the cup 2 . In such an embodiment example , the insert 3 can also not be fixed to the cup 2 , but only resting on the bottom 9 . To allow the insert 3 to remain correctly in position in the bottom 9 of the cup 2 , a sealing disc 5 , of which more details will be provided hereafter, is fixed on the plane of a step portion 23 of the cup 2 , at the upper closure of the bottom 9 .

[0036] In the examples of Figure 4B and 5B, the discoidal portion 31 of the insert 3 ends with a flat wall 35 which, together with the raised wall 36 , defines a step of the insert 3 . In the example of Figure 4B, the insert 3 is provided with only one step ; in the example of Figure 5B, the insert 3 is provided with two steps , in succession . The step of the insert 3 contributes to correctly holding the insert 3 in position inside the cup2 and to uniformly discharging the pressure of the beverage extraction step directly on the bottom of the extraction chamber of the machine , avoiding unwanted deformations of the insert 3 or of the cup 2 . In particular, in the example of Figure 5B in which the insert 3 is provided with two steps in succession, and the contact surface between insert 3 and cup 2 is maximi zed .

[0037] The flat wall 35 of the insert 3 is positioned abutting on the plane of a step portion 23 of the cup 2 . In such embodiment examples , the insert 3 is fixed to the cup 2 at the flat wall 35 . In such embodiment examples , a sealing disc 5 , of which more details will be provided hereafter, is fixed on the flat wall 35 of the insert 3 .

[0038] The capsule 1 comprises a cover 6 welded, by heat sealing or by ultrasound, on the upper edge 22 to seal the cup 2 above .

[0039] The outer casing of the capsule 1 is therefore obtained by j oining the cup 2 and the cover 6 together, as in Figure 1 .

[0040] The cover 6 is a flexible film obtained by bubble extrusion or by extrusion followed by lamination .

[0041] Preferably, the cover 6 is a film provided with a lower layer, intended to be fixed to the cup 2 , made of a thermally compostable plastic material compatible withthe material used to make the inner lining 4 covering the entire inner surface of the cup 2 .

[0042] Even more preferably, such a lower layer is made of the same compostable plastic material used to make the inner lining 4 . Such a solution ensures that , even at high pressure levels inside the capsule 1 , the cover 6 does not delaminate and therefore does not tear, detaching from the edge 4 of the cup 2 on which it is welded .

[0043] Preferably, both the cup 2 and the cover 6 have barrier properties .

[0044] Advantageously, since the cup 2 is made of cellulose and the cover 6 is made of compostable plastic material , it is possible to dispose of the exhausted capsule directly into the compostable bin, even at home .

[0045] The capsule 1 comprises a sealing disc 5 , arranged inside the cup 2 , between the cover 6 and the insert 3 , which forms the lower closure of the capsule 1 . In fact , the inner volume V in which the food substance is contained is defined between the cover 6 and the disc 5 . Preferably, the sealing disc 5 is compostable .

[0046] Advantageously, as will be better explained hereafter, the insert 3 is the element of the capsule which collects the main functional elements therein which require , for an optimal operation of the capsule , verycomplex geometries and extremely small dimensions . Since the insert 3 is made by inj ection moulding, it is possible to precisely obtain such geometries , which is not feasible with cellulose .

[0047] As seen for example in Figure 3A, the insert 3 makes the inner base of the cup 2 . In fact , the insert 3 is provided, on the upper surface of the discoidal portion 31 , with a plurality of vertically protruding reliefs , on the surface of which the sealing disc 5 forming the closure of the capsule 1 is fixed, by gluing or welding .

[0048] In the example of Figure 3A, the cup 2 is provided with an inner peripheral edge 60 on which the sealing disc 5 is fixed, by means of gluing or welding . The inner peripheral edge 60 is placed at a step portion 23 ; in the case of a pair of step portions 23 , preferably at the lower step portion 23 .

[0049] In the examples of Figure 4A and 5A, the insert 3 is provided with an inner peripheral edge 60 on which the sealing disc 5 is fixed, by gluing or welding . The inner peripheral edge 60 is placed at a flat wall 35 ; in the case of a pair of flat walls 35 ( as in Figure 5B ) , preferably at the lower flat wall 35 .

[0050] In an embodiment example , the disc 5 is fixed to the inner peripheral edge 60 in an at least partially releasable manner, so as to detach at least partiallytherefrom due to the increase in pressure inside the volume V in which the food substance S is contained . In such an example , shown in Figure 4A, the insert 3 is provided with bevelled and rounded supports 63 , adapted to keep the disc 5 raised (without puncturing or tearing it ) , preventing it from deforming excessively, obstructing the outflow of the beverage towards the outflow openings 341 .

[0051] In a further embodiment example , shown in Figure 3B, the disc 5 is fixed at the inner peripheral edge 60 in a permanent manner, and is preferably provided with weakenings 51 ( for example pre-incisions ) , so as to at least partially tear due to the ef fect of the increase in pressure inside the volume V in which the food substance S is contained .

[0052] In a still further embodiment , the disc 5 is permanently fixed at the inner peripheral edge 60 and the insert 3 is provided with tips ( obtained for example by making the supports 63 pointed and / or sharp ) adapted to at least partially pierce the disc due to the increase in pressure inside the volume V in which the food substance S is contained .

[0053] In use , the capsule 1 is inserted in a special seat provided in the extraction machine , which pierces the cover 6 and inserts a pressurised fluid (mostly hotwater ) inside the inner volume V in which the food substance S is contained . The pressure exerted by the fluid inside the capsule 1 rises until it reaches a certain threshold level , or opening pressure , which pushes the disc 5 to tear it in the case of the disc with weakenings , to detach it from the peripheral edge 60 on which it is fixed in the case of the peelable disc, or to pierce it against the tips of the base where present .

[0054] Preferably, the insert 3 comprises at least one labyrinth portion 65 of substantially annular shape , arranged between the peripheral edge 60 and the outflow openings 341 . The labyrinth portion 56 is provided with a plurality of channels , closed above by the disc 5 , of the capillary type , i . e . , which allow the outflow of the beverage at the extraction pressure , and prevent or reduce the passage when the pressure inside the capsule 1 falls below a threshold value to avoid or reduce dripping at the end of dispensing . The capillary channels are ducts with very narrow section, for example less than or equal to 1 mm2 . Preferably, the channels have a zig- zag or " square wave" pattern . Pre ferably, the labyrinth 30 comprises a number of capillary channels between 10 and 40 , preferably between 20 and 30 .

[0055] Preferably, the insert 3 is provided, between the peripheral edge 60 and the labyrinth portion 65 , with acollection hollow 66 adapted to collect the infused beverage and to allow the outflow thereof towards the labyrinth portion 65 .

[0056] Preferably, the insert is provided, between the labyrinth portion 65 and the outflow openings 341 , with a conveying hollow 67 followed by an overflow wall 68 . Such a solution avoids an excessively rapid and uncontrolled outflow of the beverage towards the outside of the capsule 1 .

[0057] Preferably, the insert 3 is provided with ribs 69 adapted to keep the disc 5 raised during the opening of the capsule so that it does not completely adhere to the bottom of the collection hollow 66 , thus preventing the outflow of the beverage . Preferably, the ribs 69 are radial protrusions arranged on the bottom of the collection hollow 66 .

[0058] In an embodiment example , the capsule 1 is a capsule for preparing beverages from an insoluble food substance , preferably insoluble cof fee . In such an embodiment example , the capsule 1 further compri ses :- below the cover 6 and above the food substance S , fixed inside the cup 2 , a containment wall 61 , called microperforated, compostable , provided with holes adapted to allow the passage of the pressurised liquid and to retain the food substance S ;- below the food substance S and above the sealing disc 5 , fixed inside the cup 2 , a compostable filtering wall 62 provided with holes adapted to allow the passage of the beverage and to retain the food substance S .

[0059] Innovatively, a capsule according to the present invention, being provided with a cellulose cup inside which a compostable plastic insert is arranged, is able to withstand the temperatures and pressures of the machines for preparing beverages , ensuring an optimal opening and dispensing of the beverage .

[0060] Advantageously, the insert is completely housed inside the cup, with the exception of the only duct with beverage outlet opening, thus remaining correctly and firmly in position for the entire duration of the extraction .

[0061] Advantageously, the compostable plastic insert is the element of the capsule which collects therein the main functional elements which require very complex geometries and extremely small dimens ions .

[0062] Advantageously, the main functional elements are made in the compostable plastic insert , and not in the cellulose cup which is sensitive to high extraction pressures and temperatures . Such a solution ensures an optimal opening of the capsule and dispensing of the beverage .

[0063] Advantageously, the capsule for preparing beverages according to the present invention is entirely compostable . With respect to the known capsules made of di f ferent plastic materials or coupled with paper or aluminium, which are very di f ficult to separate from each other when collecting waste , the capsule which is the subj ect matter of the present invention is easily recyclable both for the final consumer and for industries which decide to invest in green solutions .

[0064] Advantageously, the capsule for preparing beverages according to the present invention is entirely compostable . With respect to the known capsules , such a capsule can be disposed of in the compostable bin, even at home .

[0065] It is clear that a person skilled in the art may make modi fications to the capsule for preparing beverages described above , all contained within the scope of protection as defined by the following claims .

Claims

CLAIMS1. Compostable capsule (1) for preparing a beverage, comprising :- a cup (2) suitable for defining an inner volume (V) in which at least one food substance is contained, said cup (2) being a single body made of cellulose and being provided, in the order, with at least: an upper edge (22) , a side wall (21) , at least one step portion (23) , a lower funnel portion (24) defining a lower opening (25) of the cup ( 2 ) ;- a cover (6) fixed to the upper edge (22) of the cup (2) , suitable for sealingly close the inner volume (V) at the top;- a sealing disc (5) arranged inside the cup (2) , adapted to sealingly close the inner volume (V) at the bottom;- an insert (3) arranged in the lower portion (24) of the cup (2) , said insert (3) being a single body made of compostable plastic, said insert (3) comprising a discoidal portion (31) below which a cylindrical portion (32) protrudes, ending in an outlet opening (34) for the beverage; wherein there is at least one outflow opening (341) between the discoidal portion (31) and the cylindrical portion (32) , for the beverage to flow out of the inner volume (V) towards the outlet opening (34) .

2. Capsule (1) according to claim 1, wherein the outlet opening (34) of the cylindrical portion (32) of the insert (3) protrudes from the lower opening (25) of thecup ( 2 ) .

3. Capsule (1) according to any one of the preceding claims, wherein the insert (3) comprises a plurality of fins (33) protruding below the discoidal portion (31) , said fins (33) being completely housed in the lower portion (24) of the cup (2) .

4. Capsule (1) according to any one of the preceding claims, wherein said discoidal portion (31) of the insert comprises a f rustoconical annular support portion (37) arranged against the lower portion (24) of the cup (2) .

5. Capsule (1) according to any one of the preceding claims, wherein said discoidal portion (31) of the insert (3) ends with a flat wall (35) arranged against a horizontal plane of a step portion (23) of the cup (2) .

6. Capsule (1) according to any one of the preceding claims, wherein said disc (5) is fixed on an inner peripheral edge (60) which is a flat wall (35) of the insert (3) or a horizontal plane of a step portion (23) of the cup ( 2 ) .

7. Capsule (1) according to claim 6, wherein said disc (5) is fixed to the inner peripheral edge (60) :- in a peelable manner, to be detached at least partially from said inner peripheral edge (60) due to the increase in pressure inside the volume (V) ; or- in a permanent manner and is provided with weakenings (51) to be torn at least partially due to the increase in pressure inside the volume (V) ; or- in a permanent manner and the insert (3) is provided with tips to pierce at least partially the disc (5) due to the increase in pressure inside the volume (V) .

8. Capsule (1) according to any one of the preceding claims, wherein the insert (3) comprises, on an upper surface of the discoidal portion (31) , a labyrinth portion (65) provided with a plurality of channels, closed at the top by the disc (5) , with a section less than or equal to 1 mm2.

9. Capsule (1) according to any one of the preceding claims, wherein the insert (3) comprises an overflow wall (68) on an upper surface of the discoidal portion (31) and upstream of the outflow openings (341) .

10. Capsule (1) according to any one of the preceding claims, wherein the cup (2) comprises an inner lining (4) being impermeable to liquids, said inner lining (4) being made of a compostable material, preferably a compostable plastic material.

11. Capsule (1) according to claim 8, wherein said inner lining (4) is a layer of polylactic acid (PLA) .

12. Capsule (1) according to any one of the preceding claims, wherein said compostable plastic of the insert (3) is polylactic acid (PLA) or compounds thereof, or polyhydroxyalkanoate (PHA) or compounds thereof.

13. Capsule (1) according to any one of the preceding claims, wherein only an end part of the cylindricalportion (32) of the insert (3) protrudes from the lower opening (25) of the cup (2) .

14. Capsule (1) according to any one of the preceding claims, wherein the insert (3) is provided with a plurality of reliefs, vertically protruding from the discoidal portion (31) , said reliefs being supports (63) and / or ribs (69) .

15. Capsule (1) according to any one of the preceding claims, wherein the insert (3) is provided with a plurality of outflow openings (341) between the discoidal portion (31) and the cylindrical portion (32) .

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