A compostable capsule for preparing beverages equipped with easy-perforation lid

Abstract

The compostable capsule that is the object of the present invention comprises a cup (2) and a compostable lid (6) consisting of an outer layer (10) with gas and / or vapor barrier properties and an inner layer (20), fastened to the edge (4) of the cup (2), which is micro-perforated film provided with a plurality of through holes (201). Furthermore, the inner layer (20) and the outer layer (10) are joined together only at the edge (4) of the cup (2). Advantageously, by virtue of the micro -perforated inner layer (20) separated from the perforated outer layer (10), the lid (6) perforates correctly, facilitating optimal dispensing of the beverage.

Description

DESCRIPTION"A COMPOSTABLE CAPSULE FOR PREPARING BEVERAGES EQUIPPED WITH EASY -PERFORATION LID"

[0001] The object of the present invention is a compostable capsule for preparing infusion or soluble beverages with a compostable and easily fracturable lid.

[0002] In the sector, capsules are known for the packaging of concentrated products (for example in the form of powder, granules or leaves) in predetermined, single-use doses, for the impromptu preparation of beverages (such as tea, coffee, herbal teas, milk, chocolate, etc.) by means of the introduction, into said capsule, of a pressurized fluid (mostly hot water) . Said flow of hot water, delivered by an extraction machine, passes through the essence to be infused or dissolved contained inside the capsule, which results in the impromptu preparation of the beverage.

[0003] Different types of automatic or semi-automatic beverage preparation machines are known in the industry. One type of machine provides for the perforation of the capsule on both sides, to allow the pressurized fluid to be injected into the cup on one side, and the beverage to flow out from the opposite side. This first type of machine is intended for capsules comprising a cup closed on both sides, respectively by a bottom, generally in onepiece with the cup, and a lid, fastened to an edge of the cup . In such appl ications , the high temperature and high- pressure extraction water enters the bottom o f the capsule and flows out from the lid, which opens by perforating itsel f at various points against an appropriate element of the exaction machine . In such a case the structure of the lid, which is generally multilayer, must firstly allow for the product to open correctly and subsequently to flow out correctly .

[0004] Looking in detail at the step of the beverage flowing out of the capsule , the extraction device of the dispensing machine comprises a plurality of piercing elements that engage with the lid and perforate it at a plurality of di f ferent zones when the pressure of the liquid inside the capsule increases . The beverage may thus flow out of the cup through the perforations made in the lid . Therefore , for the dispensing to be success ful , the perforating elements of the machine need to correctly perforate the lid and the resulting perforations need to remain open during the entire dispensing of the final product .

[0005] Compostable capsules are known in industry wherein the cup and lid are made entirely of compostable material . In such capsules , the choice of compostable film with which to make the lid is particularly dif ficultin that the lid itsel f must be easy to perforate , easy to fasten to the cup, and guarantee the airtightness of the capsule . Known examples of lids made from compostable films are shown in the documents EP 3 362 377 Bl , WO 2018 / 083564 Al and EP 3 368 448 Bl . In such known examples , the inner and outer layers are j oined together uni formly, i . e . in every zone of the lid, to form a single multilayer structure .

[0006] Known compostable films have a multilayer structure comprising at least an outer barrier layer and an inner filtering layer made of paper or non-woven fabric (NWF) . The filtering layer acts as a filter for the final product to be dispensed, which is particularly advantageous i f the initial product is non-soluble cof fee in powder form . Disadvantageously, in the case of such known compostable fi lms , it may happen that dispensing stops after a few seconds without having been properly completed or even that the dispensing machine blocks . The reason for this has been identi fied by the fact that , after the first perforations , the pressure of the fluid within the capsule reduces and such a reduced pressure does not allow the outer barrier layer to be perforated any further . Under these conditions , the filtering layer made of paper or NWF, stressed by the pressure inside the capsule , tends to insert itself into the perforationsgenerated in the multilayer film and to obstruct them, thereby interrupting the dispensing o f the final product .

[0007] Known structures comprising an inner filtering layer made of paper or non-woven fabric NWF have several disadvantages :- the pores of such layer are meshes that may stretch under the pressure of the high-pressure liquid, thereby allowing the insoluble food product in powder form to infiltrate into the meshes themselves , ef fectively clogging the system and af fecting the proper functioning thereof and thus preventing proper di spens ing; such layer, of a porous type with pores having a totally random distribution, also serves as the layer that welds with the capsule ; this non-uni form distribution of the pores renders the zone that welds with the edge of the capsule body uneven, thereby leading to uneven weldability profiles .

[0008] The obj ect of the present invention is to make a capsule with a compostable lid that solves the problems encountered with lids in the known art .

[0009] In particular, the obj ect of the present invention is to make a capsule wherein the compostable lid ensures the correct implementation of the perforations and good quality of the beverage extraction .

[0010] This obj ect is achieved by a capsule according toclaim 1 . The dependent claims describe preferred embodiments of the invention .

[0011] The features and the advantages of the invention will appear more clearly from the following description, made by way of an indicative and non-limiting example with reference to the accompanying figures , wherein :- Figures 1 and 2 show, respectively, a lateral view and an axonometric view of a capsule for making infusion or soluble beverages , provided with a lid according to the present invention;- Figures 3a to 3c show, in a lateral view, the steps of opening the capsule ;Figures 4a to 4c show, in an axonometric cross- sectional view, the steps of opening the capsule ;Figure 5 shows schematically a section of the lid according to this invention, in one embodiment .

[0012] With reference to the attached figures , a capsule for preparing infusion ( i . e . from an insoluble food powder ) or soluble beverages ( i . e . from a soluble food powder ) is shown, indicated by reference number 1 .

[0013] Capsule 1 comprises a cup 2 suitable for defining an inner volume in which at least one substance to be infused or dissolved is typically contained in powder or granular form .

[0014] The cup 2 is provided on one s ide , with a closedbottom 3 and, on the opposite side, with an opening defined by an externally projecting edge 4. Capsule 1 comprises a compostable lid 6 fastened to the edge 4 for sealing the capsule. In use, the extraction water, at high temperature and high pressure, enters from the bottom 3 of the cup 2 and flows out from the lid 6, which opens by perforating itself at various points against an appropriate element of the extraction machine.

[0015] The lid is formed by two layers 10,20 separate from each other, i.e., not glued or otherwise joined in such a way that they are not integral when in motion, except at edge 4 of the cup 2, which is the only zone where these two layers 10,20 are joined together to form a single body. In other words, assuming that the lid 6 is cut transversally as in Figure 4a, a joining zone would be noted at the outer perimeter 204 of the lid 6, corresponding to the welding zone with the edge 4 of the cup 2, and a separation zone in the remaining part of the lid 6, called the central zone 203. In the joining zone, the two layers 10,20 are permanently joined to form one body, while in the separation zone the two layers 10,20 are separate bodies and therefore are not integral in motion but can freely move away from each other due to the push of the beverage inside the cup 2, as shown inFigure 4b.

[0016] The compostable lid 5 thus comprises an outer layer10 and an inner layer 20 , and it is the inner layer 20 that is in contact with the cup to seal the capsule 1 .

[0017] The outer layer 10 is a barrier layer from gas , light and vapor . For example , it has barrier properties against oxygen, humidity, water, fats , aromas and light . Such properties may alternatively derive from processing that does not include surface treatments , or else from surface treatments , such as for example metalli zation .

[0018] The outer layer 10 is a brittle fi lm, that is to say with appropriate brittleness characteristics , capable of appropriately fracturing itsel f against the perforating elements of the dispensing machine . The brittleness is to be understood, for example , as the least possible elongation following breakage and perforation on the part of the perforating elements of the di spens ing machine .

[0019] In one embodiment , the outer layer 10 is made of paper, or regenerated cellulose .

[0020] The outer layer 10 preferably has a uni form thickness of between 10 pm and 90 pm .

[0021] The outer layer 10 has a weight that is variable between 5 and 120 gsm, more preferably between 15 and 90 gsm .

[0022] In the case of the outer layer 10 being made of paper, preferably, the paper has barrier propertiesderiving solely from the dense adhesion of the paper microfibers and not deriving from the depositing of chemical lacquers or coating or metalli zation treatments . Furthermore , the paper is not comparable to a vegetable parchment that is to say it does not include the use of sul furic acid and / or zinc chloride .

[0023] In one embodiment , the barrier properties of the paper may be incremented by means of appropriate surface treatments ( such as , for example , metalli zation) that do not af fect the compostability of the paper itsel f according to current standards .

[0024] In the case of the outer layer 10 being made of regenerated cel lulose with barrier properties , the regenerated cellulose comprises a cellulose based central layer and two outer coverings , for example based upon PVDC, PVOH lacquer, silicon or aluminum oxides or a metallic aluminum-based metalli zation . The regenerated cellulose outer layer 10 has a reduced thickness and suf ficient sti f fness to be easily breakable when exposed to working pressures or to those perforating elements that exist in beverage extraction machines .

[0025] It should be noted that the inner layer 20 is a micro-perforated film . In other words , the inner layer 20 is provided with a plurality of through holes 201 .

[0026] Preferably, the texture of the micro-holes of theinner layer 20 is optimized to ensure the best lid properties. Preferably, the diameter of the micro-holes 201 is between 0.1 mm and 1.0 mm, and even more preferably between 0.3 mm and 0.8 mm. Preferably, the density of micro-holes is between 5 and 25 micro- holes / cm2, even more preferably between 8 and 20 microholes / cm2.

[0027] The micro-perforated inner layer 20 is made of a plastics material that is chemically similar and weldable to the edge 4 of the cup 2 of the capsule.

[0028] The micro-perforated inner layer 20 is made of compostable material, for example polylactic acid (PLA) or another biopolymer that is similar to the material of the cup .

[0029] The lid 6 may be obtained in two ways:- by providing two separate coils, a first coil making the outer layer 10 and a second coil making the inner layer 20, which are joined together (only at the edge 4 of the cup 2) when simultaneously fastening on the edge 4 of the cup 2;- by providing a single coil consisting of an outer layer 10 and an inner layer 20 joined together loosely, i.e. in a peelable manner, wherein such outer layer 10 and inner layer 20 are first separated from each other (i.e. mechanically delaminated) and then joined together (onlyat the edge 4 of the cup 2 ) when simultaneously fastened on the edge 4 of the cup 2 .

[0030] During the packaging of capsule 1 , and in particular during the welding step of the lid 6 on the edge 4 of the capsule 1 , as a result of the action of heat sources , and by exploiting their mutual chemical af finity, the adhesion between the inner layer 20 and the outer layer is obtained . Following such a welding action, this adhesion is higher and has values that are greater than 1 . 00 N / 15mm, preferentially greater than 5 . 00 N / 15mm, only within those zones that are subj ect to welding, whereupon the welding bars have acted .

[0031] In a further embodiment , the lid 6 has regions wherein the inner layer 20 and the outer layer 10 are fastened together in regions at a high level of adhesion . Such regions are , for example , at least one point , preferably a plurality of points , obtained by means of spot welds between the inner layer 20 and the outer layer 10 . In a further embodiment , these regions are a grid with a high level of adhesion .

[0032] Once cup 2 has been filled with a food substance , the lid 6 is welded to the edge 4 of the cup 2 in order to seal the capsule 1 at the top . Frequently, some days after the packaging, during the storage step of the capsule 1 that has been filled with a food substance suchas cof fee in powder or granular form, so-called outgassing occurs . This is a natural phenomenon wherein the cof fee powder loses and releases gases , principally carbon dioxide , that form within the food substance during roasting . The outgassing gas increases the pressure inside the cup 2 and the action of such pressure causes the inner layer 20 to move away from the outer layer 10 , thus creating a thrust chamber 205 . During the extraction step of the capsule 1 in the extraction machine , the extraction liquid accumulates within the thrust chamber 205 thereby generating a push towards the outside of the outer layer 10 , which is thus pushed to tear against the perforating elements of the di spensing machine . A plurality of beverage outlet openings 206 is thus easily and correctly formed within the outer layer 10 . Such a solution ensures the correct opening of capsule 1 and the correct dispensing of the beverage .

[0033] In the case wherein outgassing is not observed, for example for food substances that are not subj ect to a loss of gas , or in the case that outgassing may be insuf ficient , the inner layer 20 moves away from the outer layer 10 nonetheless during the initial extraction step of the capsule 1 . During the extraction step of the capsule 1 in the extraction machine , the action of the pressure of the hot liquid inside the cup 2 causes theinner layer 20 to move away from the inner layer 10 , thus creating a thrust chamber 205 . The extraction liquid accumulates within such a thrust chamber 205 for a fraction of a second, thereby generating a push towards the outside of the outer layer 10 , which is pushed to tear against the perforating elements of the di spensing machine . A plurality of beverage outlet openings 206 is thus easily and correctly formed within the outer layer 10 . Such a solution ensures the correct opening of capsule 1 and the correct dispensing of the beverage .

[0034] By virtue of the presence of the micro-perforated inner layer 20 , interposed between the food substance contained within the cup 2 and the outer layer 10 , the final product passes through the micro-perforated layer before intercepting the outer layer 10 and the pressure of the final product is thus evenly distributed over the outer layer 10 ensuring that it is perforated evenly . Furthermore , by virtue of the fact that the microperforated inner layer 20 is separate from the outer layer 10 , the perforations within such outer layer 10 are not blocked in any way .

[0035] Obviously, at the edge 4 of the cup 2 , the inner layer 20 and the outer layer 10 remain firmly welded .

[0036] In one embodiment , shown in Figure 5 , the outer layer 10 consists of an outermost substrate 101 followedby an innermost substrate 103 , j oined together by a j oining substrate 102 .

[0037] The innermost substrate 103 is made of paper or regenerated cellulose . The outermost substrate 101 is a filtering element made of compostable filter paper or non-woven fabric (NWF) . The j oining substrate 102 is an extruded compostable bio-polymer or a compostable adhesive . This solution is particularly useful for certain types of filling products , such as particularly fine insoluble cof fee powders .

[0038] Innovatively, a compostable capsule equipped with a compostable lid according to the present invention provides an improved perforation opening in that :- the micro-holes of the micro-perforated layer do not widen and do not risk being clogged with powdered food product ;- the micro-perforated layer is not impregnated with the beverage and does not compromise the correct di spensing of the beverage ;- the micro-holes are uni formly distributed within the micro-perforated ensuring a uni form welding zone with the edge of the capsule body leading to uni form weldability profiles ;- the outer layer, of a brittle material , has the obj ect of fracturing itsel f against appropriate perforatingelements that are found within the dispensing machine thereby favoring the dispensing of the beverage itself; the lid, in the entirety thereof, has barrier properties against gases, vapors, oils, fats and aromas.

[0039] It is understood that a person skilled in the art could make modifications to the capsule for the preparation of infusion or soluble beverages described above, all of which are contained within the scope of protection as defined by the following claims.

Claims

Claims1. A compostable capsule (1) for preparing pressure- extractable beverages, comprising:- a cup (2) made of a compostable material and provided with a bottom (3) , an opposite edge (4) , and an inner volume containing at least one food substance to be infused or dissolved;- a lid (6) made of a compostable material, said lid comprising : an outer layer (10) with gas and / or vapor barrier properties ;- an inner layer (20) fixed to the edge (4) of the cup (2) , said inner layer (20) being a micro-perforated film provided with a plurality of through holes (201) ; wherein said inner layer (20) and said outer layer (10) are joined together only at the edge (4) of the cup (2) .

2. A capsule (1) according to claim 1, wherein said inner layer (20) and said outer layer (10) are separate from each other, i.e. not glued or otherwise joined, except at the edge (4) of the cup (2) .

3. A capsule (1) according to any one of the preceding claims, wherein said lid (6) has:- a joining area, defined as the outer perimeter (204) , at the edge (4) of the cup (2) , wherein in the joining area said inner layer (20) and said outer layer (10) arepermanently joined to form a single body;- a separation area, defined as the central zone (203) , in the remaining part of the lid (6) , wherein in the separation area said internal layer (20) and said external layer (10) said inner layer (20) and said outer layer (10) are distinct and non-solid bodies in motion.

4. A capsule (1) according to any one of the preceding claims, wherein said outer layer (10) is made of paper or regenerated cellulose.

5. A capsule (1) according to any one of the preceding claims, wherein the diameter of the micro-holes (201) of the micro-perforated inner layer (20) is between 0.1 mm and 1.0 mm, and even more preferably between 0.3 mm and 0.8 mm.

6. A capsule (1) according to any one of the preceding claims, wherein the density of the micro-holes (201) of the micro-perforated inner layer (20) is between 5 and 25 micro-holes / cm2 , even more preferably between 8 and 20 micro-holes / cm2.

7. A capsule (1) according to any one of the preceding claims, wherein the micro-perforated inner layer (20) is made of polylactic acid (PLA) , preferably provided with an aluminum oxide or silicon oxide surface coating.

8. A capsule (1) according to any one of claims 1 to 5, wherein the micro-perforated inner layer (20) made of abiopolymer which may be heat-sealable to the compostable material of the cup (2) , preferably with an aluminum oxide or silicon oxide surface coating.

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