capsule

Abstract

The present invention relates to a capsule comprising: (i) a body comprising a first material and having a closed end and an open end; (ii) a rim comprising a first portion and a second portion, the rim comprising a second material; and (iii) a liner comprising a third material, wherein the liner is laminated to the inner surface of the body; and the rim is fixed to the open end of the body by the first portion via the liner; to a method for the manufacture of the capsule, and to a packet comprising a plurality of the capsules. [Figure 1]

Description

[0001] CAPSULE

[0002] Field of the invention

[0003] The present invention relates to capsules and a method for their production.

[0004] Background of the invention

[0005] Aluminium-based capsules for use in, for example, coffee capsule machines are well-established. The use of aluminium results in a capsule having a very high strength. This is advantageous because the capsules are exposed to extremely harsh conditions during extraction in existing extraction machines: the water employed for extraction is typically at a temperature of ~92 °C and a pressure of ~1.5 bar. Furthermore, the centrifugal extraction process required in such machines can generate forces of up to 500 N acting on the capsule rim. Current aluminium-based capsules are rigid and geometrically stable during this extraction process. The presence of a curled capsule rim (comprising a top curl and a bottom curl) on the aluminium capsules also helps to ensure the resultant beverage (e.g. coffee) has the desired level of foaming, which is caused by liquid entering the top curl during centrifugation.

[0006] However, there is increasing consumer pressure to offer packaging that is more sustainable and environmentally-friendly. In particular, there is a desire to expand the use of paper-based packaging such that the packaging can be easily composted or recycled after use. Paper-based coffee capsules are known, but the materials required to meet these environmentally-friendly goals mean that the final capsules are inherently less robust than current aluminium-based capsules and they are not able to withstand the necessarily harsh conditions of extraction in existing machines (e.g. they may break and / or get stuck in the machine). Accordingly, there exists a need to provide capsules that are able to be used in existing capsule machines and can withstand the harsh conditions applied during extraction therein, which are also easily composted or recycled after use.

[0007] Summary of the invention

[0008] Viewed from a first aspect, the present invention relates to a capsule comprising:

[0009] (i) a body comprising a first material and having a closed end and an open end;

[0010] (ii) a rim comprising a first portion and a second portion, the rim comprising a second material; and

[0011] (iii) a liner comprising a third material, wherein the liner is laminated to the inner surface of the body; and the rim is fixed to the open end of the body by the first portion via the liner.

[0012] Viewed from a further aspect, the present invention relates to a packet comprising a plurality of capsules as hereinbefore described.

[0013] Viewed from a further aspect, the present invention relates to a method for manufacturing a capsule, the method comprising the steps of:

[0014] (i) forming a body comprising a first material and having an open end and a closed end;

[0015] (ii) forming a rim comprising a first portion and a second portion wherein the second portion is curled, the rim comprising a second material; and

[0016] (iii) laminating the inner surface of the body with a liner comprising a third material such that the liner fixes the rim to the open end of the body by the first portion to give the capsule.

[0017] Viewed from a further aspect, the present invention relates to a capsule obtained by or obtainable by the method as hereinbefore described. Brief description of the drawings

[0018] Additional features and advantages of the present invention are described in, and will be apparent from, the description of the presently preferred embodiments which are set out below with reference to the drawings in which:

[0019] Figure la is a schematic showing how the components of a capsule according to the present invention are assembled together. Figure lb shows the same capsule once assembled. The depicted capsule comprises a body 1, a rim 2 and a liner 3; and

[0020] Figure 2 is a schematic showing how the rim of a capsule of the present invention may be curled to have a top curl 4 and a bottom curl 5.

[0021] Detailed description of the invention

[0022] As used herein, the term "thermoformable" refers to the ability of a material to be moulded and shaped under the application of heat and pressure.

[0023] As used herein, the term "biodegradable polymer" means a compostable polymer that occurs in nature, and which has not been processed or modified in any way that changes its chemical composition.

[0024] As used herein, the term "compostable" refers to a material that will biodegrade in a composting system within six months.

[0025] Viewed from a first aspect, the present invention relates to a capsule comprising:

[0026] (i) a body comprising a first material and having a closed end and an open end;

[0027] (ii) a rim comprising a first portion and a second portion, the rim comprising a second material; and

[0028] (iii) a liner comprising a third material, wherein the liner is laminated to the inner surface of the body; and the rim is fixed to the open end of the body by the first portion via the liner. In preferred capsules of the present invention, the first material is cellulosic moulded pulp. Preferably, the cellulosic moulded pulp is derived from wood, jut, bagasse, hemp, straw, bamboo and combinations thereof, more preferably from wood, jut, bagasse, hemp, and combinations thereof. Such materials have a high compostability.

[0029] In preferred capsules of the present invention, the second material is a cellulosic material or a thermoformable biodegradable polymer.

[0030] In preferred capsules of the present invention, the second material is a cellulosic material, preferably cellulosic moulded pulp. When the second material is a cellulosic material, the capsule has a higher overall compostability and is therefore more environmentally friendly.

[0031] In preferred capsules of the present invention, the second material is cellulosic moulded pulp. Preferably, the cellulosic moulded pulp is derived from wood, jut, bagasse, hemp, straw, bamboo and combinations thereof, more preferably from wood, jut, bagasse, hemp, and combinations thereof.

[0032] In alternative preferred capsules of the present invention, the second material is a thermoformable biodegradable polymer. Preferably, the thermoformable biodegradable polymer is selected from polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS- A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), or combinations thereof.

[0033] The use of a thermoformable biodegradable polymer such as those described above for the second material above results in a stronger rim compared to one prepared from a cellulosic material, meaning that a smaller rim thickness can be achieved. Thermoformable biodegradable polymers have the added advantage of rendering the curling step of the rim easier to perform. In preferred capsules of the present invention, the thermoformable biodegradable polymer has a melt flow index (MFI) of greater than 5 g / 10 min measured according to ISO 1133, preferably greater than 5.5 g / 10 min, more preferably greater than 6 g / 10 min, even more preferably greater than 7 g / 10 min.

[0034] In preferred capsules of the present invention, the first material and the second material are different.

[0035] In preferred capsules of the present invention, the third material is a thermoformable biodegradable polymer. Preferably, the thermoformable biodegradable polymer is selected from polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), or combinations thereof.

[0036] In preferred capsules of the present invention, the thermoformable biodegradable polymer has a melt flow index (MFI) of greater than 5 g / 10 min measured according to ISO 1133, preferably greater than 5.5 g / 10 min, more preferably greater than 6 g / 10 min, even more preferably greater than 7 g / 10 min.

[0037] In preferred capsules of the present invention, the second material and the third material are the same. When the second material and the third material are the same, preferably the rim and the liner are integrally formed.

[0038] In preferred capsules of the present invention, the liner has a thickness of 20 to 200 pm, preferably 60 to 150 pm.

[0039] In preferred capsules of the present invention, the liner comprises one or more barrier layers. The barrier layers act to protect the contents of the capsule from external factors such as water vapour and / or oxygen, and therefore extend the useable life of the capsule.

[0040] In preferred capsules of the present invention, the liner comprises one or more organic barrier layers. Preferably, the organic barrier layer(s) is selected from polyvinyl alcohol (PVOH), ethylene-vinyl alcohol (EVOH), polyglycolide (PGA), butenediol vinyl alcohol co-polymer (BVOH), or mixtures thereof.

[0041] In preferred capsules of the present invention, the liner comprises one or more inorganic barrier layers. Preferably, the inorganic barrier layer(s) is selected from aluminium, aluminium oxide (AIOX), silicon oxide (SiOx), or combinations thereof.

[0042] In the capsules of the present invention, the body and the rim are separate parts, i.e. they are formed separately and then fixed together via the liner as shown in Figure 1. The fact that the body and rim are separate parts has the advantage that a different thickness of the two parts can be accommodated within the same capsule. For example, the body may have a greater thickness than the rim, allowing for a strong body that is resistant to cracking during extraction in an extraction machine whilst maintaining a thinner rim to enable the capsule to be retrofitted to existing extraction machines and avoid back-flow problems therein. The structure of the capsules of the present invention means that the capsules are able to withstand the necessarily harsh conditions of extraction in existing machines because it allows forces to be redistributed more homogeneously between the rim and the body.

[0043] In preferred capsules of the present invention, the thickness of the rim is less than or equal to 0.4 mm. When the rim has such a thickness, extraction of the contents of the capsule can be achieved whilst avoiding back-flow problems occurring in the extraction machine. This helps to extend the shelf life of the extraction machine. In preferred capsules of the present invention, the thickness of the rim is greater than or equal to 0.05 mm. When the rim has such a thickness, the capsule can be easily used in existing extraction machines, e.g. ones originally designed for aluminium capsules.

[0044] In preferred capsules of the present invention, the thickness of the rim is 0.05 mm to 0.4 mm, more preferably 0.05 mm to 0.3 mm, even more preferably 0.1 mm to 0.3 mm.

[0045] In preferred capsules of the present invention, the thickness of the body is 0.1 mm to 1.0 mm, preferably 0.2 mm to 0.8 mm.

[0046] In preferred capsules of the present invention, the second portion of the rim is curled. Preferably, the second portion has a top curl and a bottom curl, for example as shown in Figure 2. That the second portion of the rim is curled helps to ensure the resultant beverage (e.g. coffee) has the desired level of foaming, which is caused by liquid going into the top curl during centrifugation in the extraction machine.

[0047] Preferred capsules of the present invention further comprise a sealing means, preferably a membrane, affixed to the rim, preferably to the first portion of the rim.

[0048] In preferred capsules of the present invention, the membrane is affixed to the rim using one or more adhesives, preferably wherein the one or more adhesives is compostable.

[0049] In alternative preferred capsules of the present invention, the membrane is affixed to the rim using a sealing method, preferably heat sealing or ultrasound sealing.

[0050] In preferred capsules of the present invention, the membrane is formed from a compostable material, preferably from a cellulosic material, such as paper, cardboard, or cellulosic moulded pulp. In preferred capsules of the present invention, the membrane comprises one or more barrier layers. The barrier layers may act to protect the contents of the capsule from external factors such as water vapour and / or oxygen, and therefore extend the useable life of the capsule.

[0051] In preferred capsules of the present invention, the membrane comprises one or more organic barrier layers. Preferably, the organic barrier layer(s) is selected from polyvinyl alcohol (PVOH), ethylene-vinyl alcohol (EVOH), polyglycolide (PGA), butenediol vinyl alcohol co-polymer (BVOH), or mixtures thereof.

[0052] In preferred capsules of the present invention, the membrane comprises one or more inorganic barrier layers. Preferably, the inorganic barrier layer(s) is selected from aluminium, aluminium oxide (AIOX), silicon oxide (SiOx), or combinations thereof.

[0053] Preferred capsules of the present invention are compostable.

[0054] In preferred capsules of the present invention, the body is at least partially filled with an edible product suitable for human consumption. Preferably, the edible product is selected from coffee, milk, tea, chocolate, or emulsified fat (e.g. a creamer), more preferably coffee, even more preferably ground coffee.

[0055] Viewed from a further aspect, the present invention relates to a packet comprising a plurality of capsules as hereinbefore described.

[0056] Viewed from a further aspect, the present invention relates to a method for manufacturing a capsule, the method comprising the steps of:

[0057] (i) forming a body comprising a first material and having an open end and a closed end;

[0058] (ii) forming a rim comprising a first portion and a second portion wherein the second portion is curled, the rim comprising a second material; and (iii) laminating the inner surface of the body with a liner comprising a third material such that the liner fixes the rim to the open end of the body by the first portion to give the capsule.

[0059] In preferred methods of the present invention, the body is formed in step (i) via a moulded pulp method.

[0060] In preferred methods of the present invention, the first material is cellulosic moulded pulp. Preferably, the cellulosic moulded pulp is derived from wood, jut, bagasse, hemp, straw, bamboo and combinations thereof, preferably from wood, jut, bagasse, hemp, and combinations thereof.

[0061] In preferred methods of the present invention, the second material is cellulosic moulded pulp. Preferably, the cellulosic moulded pulp is derived from wood, jut, bagasse, hemp, straw, bamboo and combinations thereof, preferably from wood, jut, bagasse, hemp, and combinations thereof.

[0062] The use of cellulosic moulded pulp as the first and / or second material means that the capsule has a higher overall compostability and is therefore more environmentally friendly.

[0063] In alternative preferred methods of the present invention, the second material is a thermoformable biodegradable polymer. Preferably, the thermoformable biodegradable polymer is selected from polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS- A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), or combinations thereof.

[0064] The use of a thermoformable biodegradable polymer such as those described above for the second material above results in a stronger rim compared to one prepared from a cellulosic material such as cellulosic moulded pulp, meaning that a smaller rim thickness can be achieved. Thermoformable biodegradable polymers have the added advantage of rendering the curling step of the rim easier to perform.

[0065] In the methods of the present invention, the first material and the second material may be the same or different. Preferably, the first material and the second material are different.

[0066] In preferred methods of the present invention, the thermoformable biodegradable polymer has a melt flow index (MFI) of greater than 5 g / 10 min as measured by ISO 1133, preferably greater than 5.5 g / 10 min, more preferably greater than 6 g / 10 min, even more preferably greater than 7 g / 10 min.

[0067] In preferred methods of the present invention, the third material is a thermoformable biodegradable polymer. Preferably, the thermoformable biodegradable polymer is selected from polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), or combinations thereof.

[0068] In preferred methods of the present invention, the thermoformable biodegradable polymer has a melt flow index (MFI) of greater than 5 g / 10 min as measured by ISO 1133, preferably greater than 5.5 g / 10 min, more preferably greater than 6 g / 10 min, even more preferably greater than 7 g / 10 min.

[0069] In the methods of the present invention, the body and the rim are separate parts, i.e. they are formed separately and then fixed together via the liner as shown in Figure 1. The fact that the body and rim are separate parts has the advantage that a different thickness of the two parts can be accommodated within the same capsule. For example, the body may have a greater thickness than the rim, allowing for a strong body that is resistant to cracking during extraction in an extraction machine whilst maintaining a thinner rim to enable the capsule to be retrofitted to existing extraction machines and avoid back-flow problems therein. The structure of the capsules prepared by the method of the present invention means that the capsules are able to withstand the necessarily harsh conditions of extraction in existing machines because it allows forces to be redistributed more homogeneously between the rim and the body.

[0070] In preferred methods of the present invention, the thickness of the rim formed in step (ii) is less than or equal to 0.4 mm. When the rim has such a thickness, extraction of the contents of the capsule can be achieved whilst avoiding back-flow problems occurring in the extraction machine. This helps to extend the shelf life of the extraction machine.

[0071] In preferred methods of the present invention, the thickness of the rim formed in step (ii) is greater than or equal to 0.05 mm. When the rim has such a thickness, the capsule can be easily used in existing extraction machines, e.g. ones originally designed for aluminium capsules.

[0072] In preferred methods of the present invention, the thickness of the rim formed in step (ii) is 0.05 mm to 0.4 mm, preferably 0.05 mm to 0.3 mm, more preferably 0.1 mm to 0.3 mm.

[0073] In preferred methods of the present invention, the body has a thickness of 0.1 mm to 1.0 mm, preferably 0.2 mm to 0.8 mm.

[0074] In preferred methods of the present invention, the second material and the third material are the same thermoformable biodegradable polymer. When the second material and the third material are the same thermoformable biodegradable polymer, step (ii) and step (iii) are preferably carried out concurrently such that the rim and the liner are integrally formed, preferably by a thermoforming process.

[0075] In preferred methods of the present invention, the laminating in step (iii) involves a thermoforming process. In the methods of the present invention, the laminating in step (iii) may or may not result in the second portion of the rim also being laminated with the liner.

[0076] In preferred methods of the present invention, the liner has a thickness of 20 to 200 pm, preferably 60 to 150 pm.

[0077] In preferred methods of the present invention, the liner comprises one or more barrier layers. The barrier layers may act to protect the contents of the capsule from external factors such as water vapour and / or oxygen, and therefore extend the useable life of the capsule.

[0078] In preferred methods of the present invention, the liner comprises one or more organic barrier layers. Preferably, the organic barrier layer(s) is selected from polyvinyl alcohol (PVOH), ethylene-vinyl alcohol (EVOH), polyglycolide (PGA), butenediol vinyl alcohol co-polymer (BVOH), or mixtures thereof.

[0079] In preferred methods of the present invention, the liner comprises one or more inorganic barrier layers. Preferably, the inorganic barrier layer(s) is selected from aluminium, aluminium oxide (AIOX), silicon oxide (SiOx), or combinations thereof.

[0080] In the method of the present invention, the second portion of the rim is curled in step (ii). Preferably, the second portion is curled such that it has a top curl and a bottom curl, for example as shown in Figure 2. That the second portion of the rim is curled helps to ensure the resultant beverage (e.g. coffee) has the desired level of foaming, which is caused by liquid going into the top curl during centrifugation in the extraction machine.

[0081] Preferred methods of the present invention comprise a further step of at least partially filling the body of the capsule with an edible product suitable for human consumption. Preferably, the edible product is selected from coffee, milk, tea, chocolate, or emulsified fat (e.g. a creamer), preferably coffee, more preferably ground coffee. Preferred methods of the present invention comprise a further step of sealing the capsule closed by affixing a sealing means, preferably a membrane, to the rim, preferably to the first portion of the rim.

[0082] In preferred methods of the present invention, the membrane is affixed to the rim using one or more adhesives, preferably wherein the one or more adhesives is compostable.

[0083] In alternative preferred methods of the present invention, the membrane is sealed to the rim using a sealing method, preferably heat sealing or ultrasound sealing.

[0084] In preferred methods of the present invention, the membrane is formed from a compostable material, preferably from a cellulosic material, such as paper, cardboard, or cellulosic moulded pulp. Such materials mean that the capsule has a higher overall compostability and is therefore more environmentally friendly.

[0085] In preferred methods of the present invention, the membrane comprises one or more barrier layers. The barrier layers may act to protect the contents of the capsule from external factors such as water vapour and / or oxygen, and therefore extend the useable life of the capsule.

[0086] In preferred methods of the present invention, the membrane comprises one or more organic barrier layers. Preferably, the organic barrier layer(s) is selected from polyvinyl alcohol (PVOH), ethylene-vinyl alcohol (EVOH), polyglycolide (PGA), butenediol vinyl alcohol co-polymer (BVOH), or mixtures thereof.

[0087] In preferred methods of the present invention, the membrane comprises one or more inorganic barrier layers. Preferably, the inorganic barrier layer(s) is selected from aluminium, aluminium oxide (AIOX), silicon oxide (SiOx), or combinations thereof.

[0088] In preferred methods of the present invention, the capsule is compostable. Viewed from a further aspect, the present invention relates to a capsule obtained by or obtainable by the method as hereinbefore described.

Claims

Claims1. A capsule comprising:(i) a body comprising a first material and having a closed end and an open end;(ii) a rim comprising a first portion and a second portion, the rim comprising a second material; and(iii) a liner comprising a third material, wherein the liner is laminated to the inner surface of the body; and the rim is fixed to the open end of the body by the first portion via the liner.

2. A capsule as claimed in claim 1, wherein the first material is cellulosic moulded pulp, preferably wherein the cellulosic moulded pulp is derived from wood, jut, bagasse, hemp, straw, bamboo and combinations thereof, preferably from wood, jut, bagasse, hemp, and combinations thereof.

3. A capsule as claimed in claim 1 or claim 2, wherein the second material is cellulosic moulded pulp, preferably wherein the cellulosic moulded pulp is derived from wood, jut, bagasse, hemp, straw, bamboo and combinations thereof, preferably from wood jut, bagasse, hemp, and combinations thereof.

4. A capsule as claimed in claim 1 or claim 2, wherein the second material is a thermoformable biodegradable polymer, preferably wherein the thermoformable biodegradable polymer is selected from polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS- A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT),cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), or combinations thereof.

5. A capsule as claimed in any one of claims 1 to 4, wherein the third material is a thermoformable biodegradable polymer, preferably wherein the thermoformable biodegradable polymer is selected from polyhydroxyalkanoates (PHAs), polyhydroxybutyrate (PHB) and co-polymers thereof, polybutylenesuccinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS- A / PBSa), polylactic acid (PLA), polybutylene adipate terephthalate (PBAT), cellulose acetate, starch, polyvinylalcohol (PVOH), ethylene vinyl alcohol (EVOH), butenediol vinyl alcohol co-polymer (BVOH), or combinations thereof.

6. A capsule as claimed in any one of claims 1 to 5, wherein the second material and the third material are the same, preferably wherein the rim and the liner are integrally formed.

7. A capsule as claimed in any one of claims 1 to 6, wherein the liner has a thickness of 20 to 200 pm, preferably 60 to 150 pm.

8. A capsule as claimed in any one of claims 1 to 7, wherein the thickness of the rim is 0.05 mm to 0.4 mm, preferably 0.05 mm to 0.3 mm, more preferably 0.1 mm to 0.3 mm.

9. A capsule as claimed in any one of claims 1 to 8, wherein the thickness of the body is 0.1 mm to 1.0 mm, preferably 0.2 mm to 0.8 mm.1710. A capsule as claimed in any one of claims 1 to 9, wherein the second portion of the rim is curled.

11. A capsule as claimed in any one of claims 1 to 10, wherein the capsule is compostable.

12. A capsule as claimed in any one of claims 1 to 11, wherein the body is at least partially filled with an edible product suitable for human consumption, preferably wherein the edible product is selected from coffee, milk, tea, chocolate, or emulsified fat (e.g. a creamer), preferably coffee, more preferably ground coffee.

13. A packet comprising a plurality of capsules as claimed in any one of claims 1 to 12.

14. A method for manufacturing a capsule, the method comprising the steps of:(i) forming a body comprising a first material and having an open end and a closed end;(ii) forming a rim comprising a first portion and a second portion wherein the second portion is curled, the rim comprising a second material; and(iii) laminating the inner surface of the body with a liner comprising a third material such that the liner fixes the rim to the open end of the body by the first portion to give the capsule.

15. A capsule obtained by or obtainable by the method of claim 14.

Images