A compostable cup with inner coating for a capsule for beverages

Abstract

A compostable cup (2) according to the present invention is a single body made of cellulose comprising: - on the one side, a lower funnel-like portion (24), defining a lower opening (31); - on the opposite side, an inlet opening (21) defined by an externally protruding edge (4); - below the edge (4), a frustoconical side wall (211), followed by a consecutive pair of step portions (23). In particular, the capsule comprises a single-layer inner coating (41), made of a liquid-impermeable compostable plastic material, applied to the inner surface of the cup (2), at least on an upper surface of the edge (4), on an inner surface of the side wall (21) and on an inner surface of the lower portion (24). Advantageously, a thus-made cup allows making a compostable cup provided with a barrier and capable of withstanding the temperatures and pressures of the machines for preparing beverages.

Description

"A COMPOSTABLE CUP WITH INNER COATING FOR A CAPSULE FORBEVERAGES" DESCRIPTION

[0001] The present invention relates to a cellulose cup for a compostable capsule for preparing beverages .

[0002] Capsules are known in the field for packaging concentrated products ( in the form of insoluble or soluble powders ) in single-use and predetermined doses , for the instant preparation of beverages ( such as cof fee , cappuccino , milk, chocolate ) by introducing a pressuri zed fluid, i . e . , hot water, into the capsule . The food powder contained inside the capsule being crossed by the hot water flow, dispensed by an extraction machine , causes the instant preparation of the beverage .

[0003] Di f ferent types of automatic or semi-automatic machines for preparing beverages are known in this field . One type of extraction includes piercing the capsule at the bottom of the cup-like body to allow the inj ection of pressuri zed hot water, and tearing the cover against the piercing means of the extraction machine to allow the beverage to exit .

[0004] Instead, the type of capsule of the present invention, adapted for use in a machine which includes piercing the capsule on only one side to allow inj ecting pressuri zed hot water into the cup-like body, is verydi f ferent . In fact , the capsule is of a complex type , comprising a cup-like body with a conduit provided with an outlet opening for the beverage , a closing cover fixed to the cup-like body, as well as its own inner opening means integral with the cup-like body . Such opening means are activated by the increased pressure inside the cuplike body to allow opening an inner sealing disc and thus allow the beverage to exit from the outlet conduit present on the bottom of the cup-like body .

[0005] With a view to the increasing attention on environmental protection, the disposal of the capsules after use takes particular importance . In particular, increasing attention is being paid to compostable materials and the need is particularly felt to provide capsules that can be thrown directly into the compostable bin, even a house bin . Therefore , cellulose capsules are known in this field .

[0006] Typically, in order to make and dispense the beverage , the hot water flow is inj ected into the capsule at a pressure that can reach 15 atmospheres for a period ranging from 15 to 90 seconds . Therefore , in order to make the capsule , it is important to select a material which provides the necessary features to withstand mechanical stresses , in particular pressure , and thermal stresses to which the capsule is subj ected in use .

[0007] The main problem of the capsules of the prior art lies in the material from which they are made , since cellulose is poorly resistant to thermal and mechanical stresses , which is typical in the field of machines for preparing beverages . Furthermore , cellulose is a porous material , which of fers no barrier, for example against air or steam, to protect the food powder contained inside the capsule .

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

[0009] In particular, it is the obj ect of the present invention to make a cup for a compostable capsule for preparing beverages which is provided with a barrier and capable of withstanding the temperatures and pressures of the machines for preparing beverages and which is capable of allowing a correct opening for dispensing the beverage .

[0010] Such an obj ect is achieved by a cellulose cup provided with an inner coating made of a liquid- impermeable , biodegradable and / or compostable plastic material .

[0011] Such an obj ect is achieved by a cup according to claim 1 . The dependent claims describe preferredembodiments of the invention .

[0012] The features and advantages of a cup for a capsule for preparing beverages according to the present invention will become apparent from the following description, given by way of non-limiting example according to the accompanying drawings , in which :- figure 1 shows an axonometric view of the outside and bottom of a capsule obtained by means of a cup of the present invention, in a constructional variant without an insert ;- figure 2 shows a section view of the capsule in figure 1 ;- figure 3 shows a section view of the lower part of the capsule in figure 1 ;- figure 4 shows an axonometric section view of the lower part of the capsule in figure 1 , with the inner disc removed for clarity;- figure 5 shows a section view of a capsule obtained by means of a cup of the present invention, in a constructional variant with an insert ;- figure 6 shows a bottom view of the capsule in figure 5 ;- figure 7A shows a section view of a cup with an insert , in a first insert embodiment ;- figure 7B shows a detail in figure 7A;figure 8A shows a section view of a cup with an insert , in a second insert embodiment ;- figure 8B shows a detail in figure 8A;- figure 9A shows a section view of a cup with an insert , in a third insert embodiment ;- figure 9B shows a detail in figure 9A;- figure 10 shows a view of the bottom portion of the insert of the capsule .

[0013] With reference to the accompanying drawings , reference numeral 2 indicates a cup of the present invention, adapted to define an inner volume V for containing at least one substance to be infused / extracted or dissolved, typically in powder or granular form .

[0014] The cup 2 is a single element , therefore a single piece .

[0015] The cup 2 is a cup-like structure , slightly f rustoconical in shape .

[0016] The cup 2 is provided, on one side , with a bottom 3 and, on the opposite side , with an inlet opening 21 defined by an externally protruding edge 4 . When used to make a capsule for preparing a beverage , the inlet opening 21 is closed by a cover 9 sealingly fixed to the edge 4 .

[0017] Below the upper edge 4 , the cup 2 comprises a f rustoconical side wall 211 , followed by at least onestep portion 23 , preferably by a consecutive pair of step portions 23 , and ending with a substantially lower funnel portion 24 , defining a lower opening 31 . Therefore , the cup 2 is externally provided, at the bottom 3 , with an opening 31 .

[0018] Throughout the present description, the bottom 3 of the cup is only identi fied with the lower funnel portion 24 .

[0019] The cup 2 is a single body, made of a compostable material . In particular, the cup 2 is made of cellulose , otherwise referred to as a cellulose pulp .

[0020] The cup 2 is made of molded cellulose pulp . The cellulose is obtained from plant fibers or recycled paper .

[0021] The cup 2 is provided with an inner surface .

[0022] The cup 2 is provided with an inner surface , intended to come into contact with a liquid, which is liquid- impermeable .

[0023] The cup 2 comprises an inner coating 411 made of a liquid- impermeable compostable material .

[0024] The cup 2 comprises an inner coating 41 made of a biodegradable and / or compostable plastic material . Such a solution improves the fixing, by welding, of an insert 300 , e . g . , made of compostable plastic, which will be discussed below .

[0025] The inner coating 411 preferably covers the entire inner surface of the cup 2. In fact, as can be seen in figures 2 and 7a, the inner coating 41 covers the upper surface of the edge 4, the inner surface of the side wall 21, and the inner surface of the lower portion 24.

[0026] The inner coating 411 is a polymer layer, i.e., it is a single layer, i.e., it consists of a single polymer layer .

[0027] The inner coating 411 is a layer of biodegradable and / or compostable polymer, such as polylactic acid (PLA) , or polyhydroxyalkanoate (PHA) , or polybutylene succinate (PBS) , or polybutylene adipate terephthalate (PBAT) , for example.

[0028] The inner coating 41 is preferably a layer of polylactic acid (PLA) .

[0029] The inner coating 411 is applied to the inner surface of the cup 2 by thermoforming. In an example of a thermoforming method, the cellulose cup 2 is inserted into a thermoforming mold and a single-layer sheet of compostable liquid- impermeable plastic material is thermoformed in the cup 2. For this purpose, the sheet is positioned above the cup 2. Thermoforming is carried out by suction means and / or blowing means adapted to deform the sheet and cause it to stick to the inner surface of the cup 2, i.e., to the bottom wall, the side wall andthe annular flange , thus obtaining the inner coating 411 . The thermoforming preferably includes a stretching step accompanied by a mandrel , where a mandrel pushes the sheet into the cup 2 .

[0030] In the context of the present description, the term sheet is used to mean the liquid- impermeable compostable plastic material before thermoforming, while the term inner coating 411 means the liquid- impermeable compostable plastic material in the cup 2 .

[0031] The sheet preferably has a thickness of about 200 microns .

[0032] As known, in the thermoforming step, the sheet is stretched and becomes thinner . However, it is essential that such a thinning does not fall below a certain minimum threshold to ensure a barrier ef fect against air and steam, and to allow correctly welding additional elements of the capsule 1 , such as the cover 9 and the sealing disc 5 .

[0033] The inner coating 411 preferably has a thickness greater than or equal to 30 microns , preferably of 40 microns , at the side wall 211 of the cup 2 . Such a solution allows providing a suitable barrier ef fect against air and steam to protect the food powder contained inside the capsule .

[0034] The welding of the cover represents a criticalaspect for the correct operation of the capsule 1 , as it af fects the correct sealing at high operating pressures of the capsule . The welding of the cover, needing to be of the permanent type, requires a certain thickness of the inner coating 411 to ensure a fixing resistant to high pressures .

[0035] The inner coating 411 preferably has a thickness at the upper edge 4 of the cup 2 greater than a thickness at the side wall 211 of the cup 2 .

[0036] The inner coating 411 preferably has a thickness greater than or equal to 100 microns , preferably of 130 microns , at the upper edge 4 ( referred to as a flange ) of the cup 2 .

[0037] The welding of the sealing disc 5 also represents a critical aspect for the correct operation of the capsule 1 , as it af fects the correct opening mode thereof .

[0038] The inner coating 411 preferably has a thickness at the step portion 23 of the cup 2 greater than a thickness at the side wall 211 of the cup 2 .

[0039] In some embodiments , the welding of the sealing disc 5 is yielding to allow opening the capsule for the outflow of the beverage . Therefore , in this case , a low level of adhesion is suf ficient between the disc and the cup, and therefore the minimum thickness of the inner coating 411 at the step portion 23 of the cup 2 can beless than the minimum thickness required for welding the cover .

[0040] The inner coating 411 preferably has a thickness at the upper edge 4 of the cup 2 greater than a thickness at the step portion 23 of the cup 2 .

[0041] The inner coating 411 preferably has a thickness greater than or equal to 80 microns , preferably of 95 microns , at the step portion 23 of the cup 2 , i . e . , of the inner peripheral edge 60 to which the sealing disc 5 is fixed . Such a solution allows correctly welding the sealing disc 5 inside the cup 2 .

[0042] 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 treated cellulose , making at least the inner surface of the cup 2 impermeable .

[0043] Said cup 2 is usable for producing a capsule for preparing infusion or soluble beverages , indicated by reference numeral 1 . When used for making a capsule for preparing a beverage , the cup 2 contains the food substance to be infused ( thus insoluble ) or the substance to be dissolved ( thus soluble ) for preparing the beverage .

[0044] Figures 2 and 5 show the use of a cup 2 according to the present invention for making a capsule 1 .

[0045] Therefore, the capsule 1 comprises a cup 2 adapted to define an inner volume V containing at least one food substance S. The cup 2 comprises an externally protruding upper edge 4, referred to as a flange, surrounding an inlet opening 21 sealingly closed by a cover 9 fixed to the upper edge 4.

[0046] The embodiment shown in figures 1-4, i.e., a cup 2 for making a capsule 1 without an insert, will now be described in detail.

[0047] In the embodiment shown in figures 1-4, the opening 31 of the cup 2 is adapted to allow the infused beverage to exit.

[0048] The outlet opening 31 is preferably defined by a nozzle 32, as shown in figure 1 and 3.

[0049] The bottom 3 of the cup 2 is concave and defines a "funnel-like" structure, which facilitates the outflow of the beverage towards the outlet opening 31.

[0050] The bottom 3 is internally provided with a plurality of inner ridges, some being radial (320) and some being circumferential (340, 23) , protruding vertically towards the inside of the cup 2. The inner circumferential ridges act as supports for a sealing disc 5 since they define, at the top thereof, a fixing surface for such a disc. The inner radial ridges act as elevations to prevent the sealing disc 5, when opening the capsule for the exit ofthe beverage, from completely sticking to the bottom 3.

[0051] The bottom 3 is also provided with a plurality of inner recesses (310, 330, 350) , defining concavities facing the inside of the cup 2, needed for collecting the beverage (e.g., the circumferential recesses) and for the correct outflow thereof towards the outlet opening 31 (e.g., the radial recesses) .

[0052] The bottom 3 of the cup 2 is also provided with a plurality of outer ridges, some being radial (930, 950) and some being circumferential (911) , protruding vertically towards the outside of the cup 2. The outer radial ridges, for example, form reinforcement ribs of the bottom 3. The outer circumferential ridges, for example, form the nozzle 32 or supports for a correct abutment of the cup 2 inside the machine infusion chamber .

[0053] The bottom 3 is also provided with a plurality of outer recesses (941, 960) , defining concavities facing the outside of the cup 2.

[0054] As can be seen from the section in figures 3 and 4, the bottom 3 of the cup 2 is defined by a wall 8 having substantially the same thickness, and it is characterized by an alternation of ridges and recesses. Note that the wall of the bottom 3 defining a ridge on the inner side is the same wall of the bottom 3 defining a recess on theouter side.

[0055] The inner ridges of the bottom 3 are internally hollow so that an outer recess is made at an inner ridge. In fact, a respective outer recess corresponds to each inner ridge of the bottom 3. And vice versa: a respective inner recess corresponds to each outer ridge of the bottom 3.

[0056] The geometry of an inner ridge substantially corresponds to the geometry of the respective outer recess .

[0057] The bottom 3 is completely devoid of sharp edges and only has spiked surfaces. All the ridges of the bottom 3, whether they are inner ridges or outer ridges, have no sharp edges. All the recesses of the bottom 3, whether they are inner recesses or outer recesses, have no sharp edges. All the ridges of the bottom are provided with an outer spiking between 0.2 and 0.5mm.

[0058] As shown in figure 3, the nozzle 32 is defined by an outer central ridge 911, preferably annular in shape, defining, at an end thereof, the outlet opening 31 of the nozzle 32. An inner central collection recess 310 corresponds, on the inner side of the bottom 3, to the outer central ridge 911.

[0059] The bottom 3 comprises an inner peripheral ridge, forming an annular step portion 23, which is flat at thetop, to which it is possible to fix a sealing disc 5 . An outer annular recess 960 is formed at the inner peripheral ridge , on the outer side o f the bottom 3 .

[0060] The bottom 3 comprises an inner annular central ridge 340 , opposing the uncontrolled outflow of the beverage towards the opening 31 . The inner central ridge 340 is formed by a plurality of sides 349 , arranged transversely to the beverage outflow direction, interspersed with passages 348 allowing a controlled outflow of the beverage towards the opening 31 . The sides 349 have an internally empty, box-like shape . A chamber 941 is made at a side 341 , protruding towards the inside of the cup 2 , on the outer side of the bottom 3 .

[0061] The bottom 3 comprises a plurality of outer radial ridges 930 , uni formly arranged about the noz zle 32 , forming reinforcement ribs on the bottom 3 of the cup 2 . As can be seen for example in figure 1 , the outer radial ridges 930 extend from the noz zle 32 to the outer annular recess 960 . Such reinforcement ribs also allow uni formly discharging the pressure of the beverage extraction step directly onto the bottom of the machine extraction chamber, avoiding undesired deformations of the cup 2 . The outer annular recess 960 al so contributes to uni formly discharging the pressure directly onto the bottom of the machine extraction chamber, avoidingundesired deformations of the cup 2 .

[0062] An inner radial channel 330 , adapted to convey the beverage towards the noz zle 32 is made inside the cup 2 , at each outer radial ridge 930 . Each inner radial channel 330 extends from the inner peripheral ridge . Each inner radial channel 330 is arranged at an opening 348 ; thereby a free path is formed for the correct outflow of the beverage .

[0063] Two inner elevations 320 extend on both sides of an inner radial channel 330 , each defined by an inner radial ridge , adapted to prevent the sealing disc 5 from completely sticking to the bottom 3 of the cup 2 when opening the capsule .

[0064] The bottom 3 comprises a plurality of outer supports 950 arranged uni formly about the outer annular recess 960 , adapted to allow the correct support of the bottom 3 of the cup 2 inside the extraction machine infusion chamber . As can be seen for example in figure 1 , the outer supports 950 is substantially trapezoidal in shape . Such outer supports also allow uni formly discharging the pressure of the beverage extraction step directly onto the bottom of the machine extraction chamber, avoiding undesired deformations of the cup 2 .

[0065] A substantially trapezoidal hollow 350 is made inside the bottom at an outer support 950 . The hollow 350is arranged between two inner elevations 320 .

[0066] The method of producing the cup 2 includes making the bottom 3 as a wall 8 , having a substantially uni form thickness , consisting of ridges and recesses , so that a corresponding inner recess is made for each outer ridge of the bottom 3 and a corresponding outer recess is made for each inner ridge of the bottom 3 . Advantageously, some outer ridges are reinforcements for the bottom 3 and at the same time they form inner recesses for the correct outflow of the beverage .

[0067] The method of producing the cup 2 includes making a single body already provided with the outlet opening 31 in the bottom 3 . Therefore , in a single step, the cup 2 already has a central portion provided with an outlet opening 31 for the outflow of the infused beverage towards the capsule 1 . Such a production method includes making a cup 2 made of cellulose ; said cup 2 being a single body provided with an inlet opening 21 and, on the opposite side , with a bottom 3 provided with a noz zle 32 ; said cup 2 having an inner base compris ing a central portion with an outlet opening 31 .

[0068] The embodiment shown in figures 5- 10 will now be described in detail , i . e . , a cup 2 for making a capsule 1 with an insert 300 .

[0069] The capsule 1 comprises an insert 300 housed insidethe cup 2.

[0070] The insert 300 is a single body, made of a compostable plastic material. The insert 300 is preferably made of PLA (polylactic acid) or compounds thereof, or PHA (polyhydroxyalkanoates) or compounds thereof. The term compound is understood to mean the material obtained by mixing the plastic base material with additives, e.g., light and heat stabilizers, flame retardants, antioxidants, fillers, pigments and dyes, lubricants and anti-lubricants, plasticizers, etc.

[0071] In a further embodiment, the insert 300 is made of cellulose pulp.

[0072] The insert 300 comprises a discoidal portion 301 from which a cylindrical portion 302 protrudes at the bottom at a central zone. Outflow openings 341 are made between the discoidal portion 301 and the cylindrical portion 302. The outflow openings 341 are obtained directly when molding the insert 300 (e.g., in figure7A) , or they are made by shearing following the step of molding the insert (e.g., in figure 7A) or by cutting and folding upon the step of molding the insert (figure 7B) .

[0073] The cylindrical portion defines a conduit 321, referred to as nozzle, terminating in a dispensing opening 34 for the beverage to exit from the capsule 1. Therefore, the beverage flows through the outflowopenings 341, is conveyed into the conduit 321, and exits from the capsule through the dispensing opening 34.

[0074] Advantageously, as can be seen from the accompanying figures, when the insert 300 is housed inside the cup 2, only the conduit 321 protrudes from the lower opening 31, i.e., it extends through and beyond the opening 31 on the bottom 3 of the cup 2. Thus, the insert 300 is completely accommodated inside the cup 2, except for the conduit 321 only, terminating in the dispensing opening 34 through which the beverage flows out. Such a solution allows correctly and firmly keeping the insert 300 in place inside the cup 3 during the beverage extraction step (which step is characterized by high pressure and temperature) , even when the insert 300 is not fixed to the cup 2 but only resting at the bottom 3 of the cup 2, as in the example in figure 7B. Instead, in the examples in figures 8B and 5B, the insert 300 is fixed to the bottom 3 of the cup 2, e.g., by welding, preferably at a step portion of both the cup and the insert.

[0075] In the capsule 1, the dispensing opening 34 for the beverage is made in the insert 300, preferably of compostable plastic, and not in the cup 2 made of cellulose, which is sensitive to high extraction temperatures and pressures. Such a solution ensures optimally dispensing the beverage.

[0076] Advantageously, the insert 300 comprises a plurality of flaps 33 uni formly distributed along the circumference , protruding below the discoidal portion 301 . As can be seen in figure 10 , the flaps 33 extend from the lower surface of the discoidal portion 301 until they reach the cylindrical portion 302 . Such flaps 33 contribute to keeping the insert 300 correctly in place inside the cup 2 . Such flaps 33 also allow uni formly discharging the pressure of the beverage extraction step directly onto the bottom of the machine extraction chamber, avoiding undesired deformations of the insert 300 or the cup 2 .

[0077] As outlined above , while the conduit 321 protrudes from the opening 31 on the bottom 3 of the cup 2 , the discoidal portion 301 is housed inside the bottom 3 of the cup 2 , and thus of the lower portion 24 ( funnel ) of the cup 2 , as can be seen in figure 7B .

[0078] The discoidal portion 301 comprises an annular support portion 37 ( also visible in figure 10 ) , which is f rustoconical in shape , adapted to abut against the lower portion 24 of the cup 2 , as can be seen in figure 7B . Such an annular support portion 37 contributes to keeping the insert 300 correctly in place inside the cup 2 and uni formly discharging the pressure in the beverage extraction step directly onto the bottom of the machineextraction chamber, preventing undesired deformations of the insert 300 or the cup 2 .

[0079] In the example in figure 7B, the discoidal portion 301 of the insert 300 ends with a raised wall 36 , positioned abutting against the rise of a step portion 23 of the cup 2 . In such an embodiment , the insert 300 can also not be fixed to the cup 2 , but only resting on the bottom 3 . In order to allow the insert 300 to remain correctly in place in the bottom 3 of the cup 2 , a sealing disc 5 , further details of which will be provided below, is fixed to the surface of a step portion 23 of the cup 2 , closing the bottom 3 at the top .

[0080] In the examples in figure 8B and 9B, the discoidal portion 301 of the insert 300 ends with a flat wall 35 which, together with the raised wall 36 , defines a step of the insert 300 . In the example in figure 8B, the insert 300 is provided with a single step ; in the example in figure 9B, the insert 300 is provided with two steps , in sequence . The step of the insert 300 contributes to keeping the insert 300 correctly in place inside the cup 2 and uni formly discharging the pressure in the beverage extraction step directly onto the bottom of the machine extraction chamber, preventing undesired deformations of the insert 300 or the cup 2 . In particular, in the example in figure 9B in which the insert 300 is providedwith two steps in sequence , the contact surface between insert 300 and cup 2 is maximi zed .

[0081] The flat wall 35 of the insert 300 is positioned abutting on the surface of a step portion 23 of the cup 2 . In such embodiments , the insert 300 is fixed to the cup 2 at the flat wall 35 . In such embodiments , a sealing disc 5 , further details of which will be provided below, is fixed to the flat wall 35 of the insert 300 .

[0082] Both in the case of the embodiment shown in figures 1-4 and in that in figures 5- 10 , the cup 2 is usable for making a capsule 1 for preparing an infused or soluble beverage .

[0083] The capsule 1 comprises a cover 9 welded, by thermoforming or ultrasound, to the upper edge 4 for sealing the cup 2 at the top .

[0084] The outer casing of the capsule 1 is thus obtained by j oining the cup 2 and the cover 9 together, as in figures 1 and 5 .

[0085] The cover 9 is a flexible film obtained by blown extrusion or by extrusion followed by roll ing .

[0086] The cover 9 is preferably compostable .

[0087] The cover 9 is preferably a film provided with a bottom layer, intended to be fixed to the cup 2 , made of a compostable plastic material which is thermally compatible with the material used for making the innercoating 41 covering the entire inner surface of the cup2 .

[0088] Even more preferably, such a bottom layer is made of the same compostable plastic material used to make the inner coating 41 . Such a solution ensures that , even at high levels of pressure inside the capsule 1 , the cover 9 does not delaminate and thus does not tear, separating from the edge 4 of the cup 2 to which it i s welded .

[0089] Both the cup 2 and the cover 9 preferably have barrier properties .

[0090] Advantageously, since the cup 2 is made of cellulose and the cover 9 is made of a compostable plastic material , it is possible to throw the used capsule directly into the compostable bin, even a house bin .

[0091] The capsule 1 comprises a sealing disc 5 , arranged inside the cup 2 to close the capsule 1 . In fact , the inner volume V containing the food substance is defined between the cover 9 and the disc 5 . The sealing disc 5 is preferably compostable .

[0092] The capsule 1 is thus provided with a closed chamber, defined at the top by the cover 9 and at the bottom by the disc 5 , containing the substance to be infused or dissolved . The presence of a hermetically- sealed chamber is important for good storage and preservation of the substance . The disc 5 is positionedbelow the food substance and above the bottom 3 .

[0093] The sealing disc 5 is preferably compostable .

[0094] In the case of the embodiment shown in figures 1-4 , the disc 5 is fixed inside the cup 2 , at the bottom 3 , on the inner peripheral ridge and on the sides 349 . The disc 5 is preferably welded by using a heat-activated material ( spray, glue , a lower polymer layer in the case of a multi-layer disc ) .

[0095] In an embodiment , the disc 5 is permanently fixed to the sides 349 and instead with a low adhesion level at the inner peripheral ridge so as to separate , i . e . , become unstuck, therefrom as a result of the increased temperature and pressure inside the capsule 1 .

[0096] In a further embodiment , the disc 5 is permanently fixed to both the sides 349 and the inner peripheral ridge , and the opening of the capsule is achieved by the collapse of the disc 5 due to the increased pressure inside the capsule 1 . In such a variant , the disc 5 preferably has weakenings , such as cuts or incisions , which result in the tearing of the disc 5 due to the increased pressure inside the capsule 1 .

[0097] In the case of the embodiment in figures 5- 10 , the sealing disc 5 is arranged inside the cup 2 , between the cover 9 and the insert 300 . Advantageously, as will be better explained below, the insert 300 is the element ofthe capsule which collects therein the main functional elements requiring very complex geometries and highly small dimensions for an optimal operation of the capsule .

[0098] As can be seen for example in figure 7A, the insert 300 forms the inner base of the cup 2 . In fact , the insert 300 is provided, on the upper surface of the discoidal portion 301 , with a plurality of vertically protruding ridges , onto the surface of which the sealing disc 5 is fixed, by gluing or welding, to close the capsule 1 .

[0099] In the example in figure 7A, the cup 2 is provided with an inner peripheral edge 60 to which the sealing disc 5 is fixed by 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 .

[0100] In the examples in figures 8A and 9A, the insert 300 is provided with an inner peripheral edge 60 to 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 9B ) , preferably at the lower f lat wall 35 .

[0101] In an embodiment , the disc 5 is fixed to the inner peripheral edge 60 in an at least partially releasable manner, so that it separates , at leastpartially, therefrom due to the increased pressure inside the volume V containing the food substance S . In such an example , shown in figure 8A, the insert 300 is provided with supports 63 , smoothed and rounded, adapted to keep the disc 5 raised (without pricking or tearing it ) , preventing it from being excessively deformed, obstructing the outflow of the beverage towards the outflow openings 341 .

[0102] In a further embodiment , shown in figure 7B, the disc 5 is permanently fixed at the inner peripheral edge 60 , and is preferably provided with weakenings 51 ( e . g . , pre-incisions ) , so as to tear, at least partially, due to the increased pressure inside the volume V containing the food substance S .

[0103] In an even further embodiment , the disc 5 is permanently fixed at the inner peripheral edge 60 , and the insert 300 is provided with tips ( obtained for example by making the supports 63 pointed and / or sharp ) , adapted to pierce at least partially the disc due to the increased pressure inside the volume V containing the food substance S .

[0104] The insert 300 preferably comprises at least one substantially annular labyrinth portion 65 , arranged between the peripheral edge 60 and the outflow openings 341 . The labyrinth portion 56 is provided with aplurality of channels , closed at the top by the disc 5 , of the capillary type , i . e . , allowing the beverage to flow out at the extraction temperature , and preventing or reducing the passage thereof when the pressure inside the capsule 1 falls below a threshold value to prevent or reduce dripping after dispensing . The capillary channels are very narrow section conduits , e . g . , less than or equal to 1 mm2. The channels preferably have a zig-zag or " square wave" development . The labyrinth portion 65 preferably comprises a number of capillary channels between 10 and 40 , preferably between 20 and 30 .

[0105] The insert 300 is preferably provided, between the peripheral edge 60 and the labyrinth portion 65 , with a collection depression 66 adapted to collect the infused beverage and allow it to flow out towards the labyrinth portion 65 .

[0106] Between the labyrinth portion 65 and the outflow openings 341 , the insert is preferably provided with a conveying depression 67 , followed by an overflow wall 68 . Such a solution avoids an excessively fast and uncontrolled outflow of the beverage towards the outside of the capsule 1 .

[0107] The insert 300 is preferably provided with ribs 69 adapted to keep the disc 5 raised when opening the capsule so that it does not completely stick to thebottom of the collection depression 66, thus preventing the outflow of the beverage. The ribs 69 are preferably radial protrusions arranged on the bottom of the collection depression 66.

[0108] In both the case of the embodiment shown in figures 1-4 and that in figures 5-10, in use, the capsule 1 is inserted into a special seat provided in the extraction machine, which pierces the cover 9 and introduces a pressurized fluid into the inner volume V in which the food substance S (mostly hot water) is contained. The pressure applied by the fluid inside the capsule 1 increases until it reaches a certain threshold level, or opening pressure, which pushes on the disc 5 to tear it if the disc has weakenings, separate it from the peripheral edge 60 to which it is fixed if the disc is peelable, or pierce it against the tips of the base where present .

[0109] The capsule 1 can be made in various versions, e.g., for preparing infusion beverages (e.g., coffee) or soluble beverages.

[0110] In the constructional variant for infusion beverages, in which the food substance contained in the capsule is coffee powder that remains as coffee grounds after dispensing, the capsule 1 comprises a filter and a micro-perforated member. The presence of the filterallows filtering the infused liquid before it exits from the capsule 1 . The micro-perforated member is a permeable film fixed at a certain distance above the substance . The presence of such a film, which al lows the pressurized fluid to pass , but not the substance , prevents the dispersion of the cof fee powder being infused, improving the quality of the infused beverage .

[0111] In such an embodiment , the capsule 1 is a capsule for preparing beverages from an insoluble food substance , preferably insoluble cof fee . In such an embodiment , the capsule 1 further comprises :- below the cover 9 and above the food substance S , fixed inside the cup 2 , a compostable containment wall 61 , referred to as micro-perforated member, provided with holes adapted to allow the pressuri zed liquid to pass and 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 beverage to pass and retain the food substance S .

[0112] In the case of the capsule for preparing soluble beverages , such as chocolate or milk, for example , the capsule 1 comprises the cover 9 and the sealing disc 5 , and has no filter nor a permeable or micro-perforated film .

[0113] The capsule 1 , in the di f ferent constructional variants thereof , is usable for preparing instant beverages ( such as tea, cof fee , herbal teas , milk, chocolate , etc . ) by means of automatic or semi-automatic machines provided with a dispensing unit adapted to produce an infusion by passing pressuri zed hot water through the capsule 1 .

[0114] Innovatively, a cup according to the present invention is made of cellulose with a single-layer inner coating made of a liquid impermeable , biodegradable and / or compostable plastic material . Advantageously, such a cup allows making a compostable cup for preparing beverages which is provided with a barrier and capable of withstanding the temperatures and pressures of the machines for preparing beverages .

[0115] Advantageously, the cellulose cup according to the present invention has a suitable thickness of the inner coating in the critical points : a suitable minimum thickness at the side wall for ensuring a barrier ef fect against air and steam and a suitable minimum thickness at the welding zones of the cover and sealing disc for making a capsule capable of withstanding the temperatures and pressures of the machines for preparing beverages and capable of allowing a correct opening for dispensing the beverage .

[0116] Advantageously, in the constructional variant shown in figures 1-4 , the cellulose cup is provided with a bottom wall which, by means of a sequence of entire recesses and ridges that form corresponding outer ridges and recesses , al lows producing a capsule provided with the necessary functional means for a correct dispensing of the beverage . Therefore , advantageously, despite being made of cellulose , the cup does not require any inner insert . This allows simpli fying the production and assembly, reducing the production costs .

[0117] Advantageously, such a compostable capsule for preparing beverages , provided with its own inner opening means , is capable of ensuring optimal opening and dispensing of the beverage .

[0118] Advantageously, such a compostable capsule , provided with a cellulose body with integrated opening means , also made of cellulose, is capable of withstanding the temperatures and pressures of the machines for preparing beverages .

[0119] Advantageously, in the constructional variant shown in figures 5- 10 , a capsule provided with a cellulose cup with an insert therein, preferably made of compostable plastic, is capable of withstanding the temperatures and pressures of the machines for preparing beverages ensuring optimal opening and dispensing of thebeverage .

[0120] Advantageously, the insert is completely accommodated inside the cup, except for j ust the conduit with the beverage outlet opening, thus correctly and firmly remaining in place for the entire duration of the extraction .

[0121] Advantageously, the insert , made of compostable plastic or cellulose pulp, is the element of the capsule that collects the main functional elements requiring very complex geometries and highly small dimens ions .

[0122] Advantageously, the main functional elements are made in the insert , of compostable plastic or cellulose pulp, and not in the cellulose cup, which is sensitive to the high extraction pressures and temperatures . Such a solution ensures optimal opening of the capsule and dispensing of the beverage .

[0123] Advantageously, in both the constructional variant in figures 1-4 and in that in figures 5- 10 , the capsule is completely compostable . As compared to the known capsules made of di f ferent plastic materials or coupled to paper or aluminum, which are very di f ficult to separate at the time of the waste collection, the capsule can easily be recycled by both the final consumer and the industries deciding to invest in green solutions .

[0124] Advantageously, the capsule for preparingbeverages is completely compostable . As compared to the known capsules , such a capsule can be thrown into the compostable bin, even a house bin .

[0125] It is apparent that those skilled in the art may make changes to the above-described cup and capsule for preparing beverages , all contained within the scope of protection as defined by the following claims .

Claims

CLAIMS1. A compostable cup (2) for a capsule (1) for preparing a beverage, said cup (2) being a single body made of cellulose comprising:- on the one side, a lower funnel-like portion (24) , defining a lower opening (31) ;- on the opposite side, an inlet opening (21) defined by an externally protruding edge (4) ;- below the edge (4) , a f rustoconical side wall (211) , followed by a consecutive pair of step portions (23) ;- a single-layer inner coating (41) , made of a liquid- impermeable compostable plastic material, applied to the inner surface of the cup (2) , wherein said inner coating (411) covers at least: an upper surface of the edge (4) , an inner surface of the side wall (21) and an inner surface of the lower portion (24) .

2. A cup (2) according to claim 1, wherein the inner coating (411) entirely covers the inner surface of the cup ( 2 ) .

3. A cup (2) according to any one of the preceding claims, wherein the inner coating (411) is polylactic acid (PLA) , or polyhydroxyalkanoate (PHA) , or polybutylene succinate (PBS) , or polybutylene adipate terephthalate (PBAT) .

4. A cup (2) according to any one of the precedingclaims, wherein the inner coating (411) has a thickness at the upper edge (4) greater than a thickness at the side wall (211) .

5. A cup (2) according to any one of the preceding claims, wherein the inner coating (411) has a thickness at the upper edge (4) greater than a thickness at the step portion (23) .

6. A cup (2) according to any one of the preceding claims, wherein the inner coating (411) has a thickness at the step portion (23) greater than a thickness at the side wall (211) .

7. A cup (2) according to any one of the preceding claims, wherein the inner coating (411) has a thickness greater than or equal to 100 microns, preferably of 130 microns, at the upper edge 4.

8. A cup (2) according to any one of the preceding claims, wherein the inner coating (411) has a thickness greater than or equal to 80 microns, preferably of 95 microns, at the step portion (23) .

9. A cup (2) according to any one of the preceding claims, wherein the inner coating (411) has a thickness greater than or equal to 30 microns, preferably of 40 microns, at the side wall (211) .

10. A cup (2) according to any one of the preceding claims, wherein the inner coating (411) is applied to theinner surface of the cup (2) by thermoforming from a sheet of liquid-permeable compostable plastic material having a thickness of 200 microns.

11. A compostable capsule (1) for preparing a beverage, comprising :- a cup (2) according to any one of claims 1 to 10; said cup (2) being adapted to define an inner volume (V) containing at least one food substance;- a cover (9) fixed to the edge (4) of the cup (2) , adapted to 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 (300) arranged in the lower portion (24) of the cup (2) , said insert (300) being a single body made of compostable plastic or cellulose pulp, said insert (300) comprising a discoidal portion (301) below which a cylindrical portion (302) protrudes, terminating in an outlet opening (34) for the beverage; wherein there is at least one outflow opening (341) between the discoidal portion (301) and the cylindrical portion (302) for the outflow of the beverage from the inner volume (V) to the outlet opening (34) , and wherein the outlet opening (34) of the cylindrical portion (302) of the insert (300) protrudes from the lower opening (31) of the cup (2) .

12. A compostable capsule (1) for preparing a beverage, comprising :- a cup (2) according to any one of claims 1 to 10; said cup (2) being adapted to define an inner volume (V) containing at least one food substance; wherein the lower opening (31) of the cup (2) is the outlet opening for the beverage ;- a cover (9) fixed to the edge (4) of the cup (2) , adapted to 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;- wherein the lower portion (24) is a wall (8) with an alternation of ridges and recesses, wherein the wall (8) defining a ridge on the inner side is the same wall (8) defining a recess on the outer side.

Images