[0001] The subject matter of the present invention is a capsule for the preparation of infusion
or soluble beverages, in particular a single-material capsule made of polyethylene
terephthalate (PET) by injection molding.
[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. The capsule that is the subject matter of the present invention
is suitable for use in a machine that envisages piercing the capsule on one side only
to allow for the injection of pressurized hot water into the cup. The capsule that
is the subject matter of the present invention is in fact of the complex type, comprising
a cup equipped with an opening for the beverage on one side and a closing cover on
the opposite side, as well as the inner opening means thereof. Such opening means
are, for example, activated by increasing the pressure within the cup so as to allow
the inner sealing disc to detach and thereby allow the beverage to be dispensed from
the outlet opening at the bottom of the cup. This type of capsule is rather complex
from the construction point of view, especially with regard to the implementation
of additional internal functional elements, such as, for example, means for supporting
the sealing disc or antidrip means in the form of a labyrinth.
[0004] Typically, to make and dispense the beverage, the flow of hot water is injected inside
the capsule with a pressure of about 20 atmospheres for a time ranging from 15 to
90 seconds. It is therefore important for the capsule manufacturer to select a material
that provides the features necessary to resist mechanical stresses, in particular
pressure, and thermal stresses to which the capsule is subjected during use.
[0005] Furthermore, with an increasing focus on environmental protection, the disposal of
such capsules at the end of their use becomes particularly important. Those capsules
that are currently commercially available are made using many types of materials and
may be confusing with respect to the correct type of container to be used when throwing
them away. This ambiguity leads consumers to forgo detailed differentiation and to
put everything in one container.
[0007] The object of the present invention is to construct a capsule for the preparation
of infusion or soluble beverages that solves the problems of the prior art while taking
into account the needs of the industry.
[0008] This object is achieved by a capsule for preparing infusion or soluble beverages
according to claim 1. The dependent claims describe preferred embodiments of the invention.
[0009] The features and advantages of a capsule for the preparation of infusion or soluble
beverages according to the present invention will become apparent from the following
description, given by way of nonlimiting example and according to the accompanying
figures, wherein:
- Fig. 1a and 1b show a capsule for preparing infusion or soluble beverages according
to the present invention that are self-opening by virtue of the effect of increasing
the internal pressure; Fig. 1a shows the capsule closed before dispensing and Fig.
1b shows the capsule open after dispensing;
- Fig. 2a and 2b are an axonometric view from above and a top view, respectively, of
a cup for a capsule for preparing infusion or soluble beverages according to the present
invention;
- Fig. 3a and 3b are an axonometric view from below and a bottom view, respectively,
of the cup of Fig. 2a;
- Fig. 4 shows a sectional view of the cup in Fig. 2a.
[0010] With reference to the figures, a capsule 1 for the preparation of infusion or soluble
beverages is shown, indicated with the reference numeral 1.
[0011] The capsule 1 comprises a body or cup 2 suitable to define an inner volume V wherein
at least one substance S to be infused or dissolved, typically in powder or granular
form, is contained.
[0012] The cup 2 is provided, on one side, with a bottom 3, and, on the opposite side, with
an inlet opening defined by an externally projecting edge 4.
[0013] The capsule 1 comprises a cover 6 fastened to the edge 4 to seal the cup 2 on top.
The cover is for example a multi-layer cover, comprising at least one barrier layer.
For example, the cover 6 comprises an outer barrier layer, made of metallized polyethylene
terephthalate, joined by means of adhesive to an inner sealing layer, made of polyethylene
terephthalate. In an alternative variant, the two outer and inner layers are co-extruded.
[0014] The capsule 1 comprises a sealing disc 5, arranged within the cup 2, which closes
the bottom of the capsule 1. The sealing disc 5 is for example a multi-layer sealing
disc, comprising at least one barrier layer. For example, the sealing disc 5 comprises
an upper barrier layer, made of polyethylene terephthalate with a barrier coating,
joined by means of an adhesive to a lower layer, made of lacquered polyethylene terephthalate.
In an alternative variant, the upper and lower layers are co-extruded.
[0015] In effect, between the cover 6 and the disc 5 the inner volume V is defined wherein
the substance S to be infused or dissolved is contained.
[0016] At the bottom 3, the cup 2 is provided with an outlet opening 31 that is suitable
for allowing the infused beverage to be dispensed. The opening 31 is the end opening
of a duct called a nozzle. The nozzle comprises a substantially cylindrical outer
portion 310 and an inner portion 313 that is provided with connection openings 314
between the inner volume V of the cup 2 and the outside of the capsule 1.
[0017] Preferably, the connection openings 314 are at most six and large in size and are
uniformly distributed along the inner portion 313.
[0018] The expression "large" means that the width of the connecting openings 314 is greater
than the thickness of the inner portion 313.
[0019] The presence of a maximum of six large connection openings 314 allows for an easy
and rapid dispensing of the beverage, thus avoiding an excessive increase in pressure
at the base during the beverage dispensing step. Advantageously, moreover, large openings
make closing the mold easier, and less prone to burrs, especially given the molding
difficulties of this family of materials.
[0020] The nozzle is closed at the top by a wall 311 which forms, internally to the cup
2, a fastening point for the sealing disc 5.
[0021] Inside the nozzle, protruding from the wall 311, there is a flow director 9 that
serves to direct the flow of the beverage towards the opening 31 and then towards
the cup of the consumer thereby greatly reducing uncontrolled leakages and splashes.
Preferably, the flow director 9 is a pin with three tips 91, each triangular in shape
and with rounded edges, as is clearly visible in Fig. 3b. Preferably, the profile
of the flow director 9 has a minimum mold release of 3° to render it easier to mold
the cup. This solution makes it possible to facilitate the extraction of the cup 2
from the mold, without risk of breakage or deformation of the injection molded part.
[0022] Preferably, the bottom 3 of the cup 2 is provided with outer reinforcement flaps
92, with a rounded profile. Preferably, the profile of the outer reinforcement flaps
92 has a minimum mold release of 5° to render it easier to mold the cup. Preferably,
the outer reinforcement flaps 92 are at least ten, preferably twelve and are evenly
distributed. Such solution allows the bottom 3 of the cup 2 to be adequately reinforced
in order to withstand the high usage pressures of the capsule 1.
[0023] The cup 2 comprises therein a base 33 provided with a plurality of vertically protruding
ridges on which surface the sealing disc 5, which closes the capsule 1, is in fact
fastened by gluing or welding.
[0024] The base 33 comprises a perimeter edge 360 on which the sealing disc 5 is attached
by gluing or welding.
[0025] The base 33 preferably comprises a labyrinth portion 320 with a drip-reducing function,
arranged about the outlet opening 31. The labyrinth portion 320 is a single annular
ridge provided, on the upper surface, with a plurality of grooves forming capillary
channels. The labyrinth portion 320 is in fact provided with a plurality of capillary
channels, i.e., with a reduced cross-section, preferably of less than 1 mm2, closed
at the top by the disc 5, and adapted to hinder the passage of the beverage due to
the capillary effect when the pressure inside the capsule 1 drops below a threshold
value. When the capsule is disengaged from the dispensing machine, the labyrinth helps
to reduce dripping of the beverage at the end of dispensing.
[0026] Preferably, the capillary channels have a Greek key pattern, i.e., they are formed
by an uninterrupted series of segments alternately arranged in a substantially perpendicular
manner, as is clearly visible in Fig. 2b. Advantageously, the length of each capillary
channel is much greater than the length of the labyrinth portion 320 when measured
along the radius of the base 33.
[0027] Preferably, as may be seen in Fig. 2b, the labyrinth portion 320 occupies a portion
that is equal to or less than the portion occupied by a valley 330 (described below),
measured along the radius of the base 33.
[0028] The base 33 is provided, between the peripheral edge 360 and the labyrinth portion
320, with a valley 330 that defines a space suitable to accommodate, without obstructing
it, the deformation of the sealing disc 5, or at least a portion thereof, when the
pressure exerted by the fluid within the capsule 1 reaches a certain opening threshold
level. The valley 330 defines a recess in the base 33 having a greater depth than
those grooves that define the capillary channels of the labyrinth portion 320. The
walls defining the valley 330 are preferably inclined walls for facilitating the extraction
of the cup 2 from the mold without risk of breakage or deformation of the injection
molded part.
[0029] Preferably, inside the valley there are supports 317, in the form of ridges with
rounded walls for the disc 5. For example, there are six supports 317 that are evenly
distributed.
[0030] A beverage collection basin 318 is defined between the labyrinth portion 320 and
the nozzle. The collection basin 318 defines a recess in the base 33 having a much
greater depth than the grooves that define the capillary channels of the labyrinth
portion 320. Preferably, the walls defining the collection basin 318 are inclined
walls for facilitating the extraction of the cup 2 from the mold, without risk of
breakage or deformation of the injection molded part.
[0031] The disc 5 is fastened to the base 33 in an at least partially releasable manner
such that it at least partially detaches therefrom by virtue of the increase in pressure
within the volume V wherein the food substance S is contained.
[0032] The disc 5 is instead permanently fastened to the labyrinth portion 320.
[0033] In use, the capsule 1 is inserted into a slot provided in the extraction machine,
which pierces the cover 6 and introduces a pressurized fluid (mostly hot water) into
the inner volume V in which the substance S is contained. The pressure exerted by
the fluid inside the capsule 1 rises until it reaches a certain threshold level, or
opening pressure (for example, between 4 and 8 bars), which pushes against the disc
5 until it at least partially deforms it and detaches it from the perimeter edge 360
on which it is fastened.
[0034] The cup 2 is made of polyethylene terephthalate (PET) by injection molding.
[0035] The cup 2 is made entirely of polyethylene terephthalate, or else of polyethylene
terephthalate combined with a material that may be similar to polyethylene terephthalate
and recycled together with polyethylene terephthalate.
[0036] In one embodiment, the cup 2 is provided with a gas and/or vapor barrier, obtained
by means of additives added to the polyethylene terephthalate.
[0037] The cup 2 is preferably made at least partially of recycled polyethylene terephthalate
r-PET.
[0038] Recycled polyethylene terephthalate r-PET (recycled PET) is a polymer obtained through
processes of recovering and recycling common PET which involve the sorting, washing,
shredding, and melting of plastics materials. Preferably, the material used is recycled
polyethylene terephthalate (r-PET) obtained from post-consumer PET bottle flakes and/or
PET bottle scraps from industrial production.
[0039] The cup 2 is therefore made entirely or predominantly of polyethylene terephthalate
PET wherein a part thereof is recycled r-PET. The percentage of recycled polyethylene
terephthalate r-PET is preferably between 20% and 100% of the total polyethylene terephthalate
PET.
[0040] The polyethylene terephthalate, also when recycled, makes it possible to obtain a
cup 2 with high thermal and mechanical resistance that may be penetrated by a flow
of liquid at high temperature (between 90° and 95°C) and pressure (between 10 and
12 bar) for the entire dispensing time (about 1 minute) without softening and deforming
(for example, at the bottom and at the nozzle) and without breaking (for example,
at the side walls).
[0041] In one exemplary embodiment, the cup 2 is made of a plastics material consisting
of polyethylene terephthalate PET (also in a recycled r-PET version) and a copolyester
that is comparable to PET and recyclable together with PET.
[0042] For example, the cup 2 is made of between 20% and 50% polyethylene terephthalate
PET, wherein a part thereof may be recycled (r-PET), and for the remaining part made
from a copolyester that is similar to PET and recyclable together with PET.
[0043] A copolyester that is comparable to polyethylene terephthalate and recyclable together
with polyethylene terephthalate is, for example, glycol-modified polyethylene terephthalate
PETG. PETG is obtained by adding modified glycol to the polyethylene terephthalate
composition during polymerization.
[0044] In one example, the cup 2 is made of a plastics material comprising 48% PET (wherein
25% thereof is r-PET) and 52% a copolyester that is similar to PET and recyclable
together with PET.
[0045] In one example, the cup 2 is made of a plastics material comprising 48% PET (wherein
25% thereof is r-PET) and 52% PETG. In this exemplary embodiment the material of the
cup 2 has the following properties:
- a density of between 1.25 g/cm3 and 1.35 g/cm3 (ISO 1183-1 standard);
- a melting temperature of between 230°C and 247°C;
- a melt-mass flow rate (MFR) of between 25 and 35 g/10' (ISO 1133 standard);
- a melt volume-flow rate (MVR) of between 20 and 30 cm3/10' (ISO 1133 standard);
- a Vicat temperature of between 85°C and 95°C (ISO 306 standard).
[0046] Preferably, the cup 2 has a wall thickness of between 0.4 mm and 0.8 mm, preferably
of between 0.5 mm and 0.6 mm.
[0047] It should be noted that the cup 2, made entirely or predominantly of polyethylene
terephthalate, does not require the addition of additives or barrier layers insofar
as the base material is already sufficient to ensure an optimal gas and/or vapor barrier.
[0048] The capsule 1 is made of polyethylene terephthalate PET, i.e., all of the components
that comprise the capsule are made, entirely or predominantly, of polyethylene terephthalate
PET.
[0049] The term "single-material" means that the capsule is entirely made using a certain
base material, or may also contain a material that may be similar to the base material
and recyclable together with the base material, or may contain negligible traces of
other materials in such a way that it may be recycled in the container of the base
material.
[0050] The capsule 1 is preferably free of metallic elements, such as, for example, aluminum,
or paper, and is therefore easily differentiated by the consumer.
[0051] The cup 2, the cover 6, the containment wall 7 where present, the filtering wall
8 where present, and the sealing disc 5 are therefore made, entirely or predominantly,
of polyethylene terephthalate PET.
[0052] In other words, the cover 6 and the sealing disc 5 are made of the same material
as the cup 2 on which they are welded. In contrast, in prior art solutions, the cover
and disc are made of materials that are thermally compatible with the constituent
material of the cup, but not the same constituent material as the cup. The fact of
selecting a material that is thermally compatible with the constituent material of
the cup allows good welding between the cover/disc and the cup to be obtained, but
does not allow for the continuity of the material of the joined parts to be obtained.
That is why, in the solutions of the prior art, there are risks of delamination due
to high pressures such as those to which an infusion coffee capsule is subjected,
i.e., greater than 10 bar, even around 15 bar. In contrast, as seen in accordance
with the present invention, the fact of selecting the same constituent material of
the cup for the cover and for the disc allows for the continuity of the material of
the joined parts to be obtained, i.e., a weld that allows for the physical/chemical
union of the two elements, and therefore a permanent connection.
[0053] Below are two embodiments of the capsule 1 according to the present invention.
CAPSULE FOR INFUSION BEVERAGES
COMPONENT |
COMPOSITION |
WEIGHT (g) |
WEIGHT (%) |
Cover (multilayer film: outer layer, adhesive, inner layer) |
Outer layer: PET with metallization in order to have a high Barrier |
0.21 |
3.9 |
Inner layer: PET welding |
Sealing disc (multilayer film: outer layer, adhesive, inner layer) |
Outer layer: PET with an added coating in order to have a Barrier |
0.05 |
0.9 |
Inner layer: PET welding |
Containment wall (Microperforated film, monolayer) |
PET |
0.04 |
0.7 |
Filtering wall (Microperforated film, monolayer) |
PET |
0.06 |
1.1 |
Cup |
rPET + PETG |
5.05 |
93.3 |
TOTAL |
|
5.41 |
100 |
CAPSULE FOR SOLUBLE BEVERAGES
COMPONENT |
COMPOSITION |
WEIGHT (g) |
WEIGHT (%) |
Cover (multilayer film: outer layer, adhesive, inner layer) |
Outer layer: PET with metallization in order to have a high Barrier |
0.21 |
4.0 |
Inner layer: PET welding |
Sealing disc (multilayer film: outer layer, adhesive, inner layer) |
Outer layer: PET with an added coating in order to have a Barrier |
0.05 |
0.9 |
Inner layer: PET welding |
Cup |
rPET + PETG |
5.05 |
95.1 |
TOTAL |
|
5.31 |
100 |
[0054] Advantageously, therefore, the capsule 1 is of a single-material, i.e., it is made
of at least 90%, preferably at least 95%, polyethylene terephthalate or polyethylene
terephthalate combined with a material that is similar to polyethylene terephthalate
and recyclable together with polyethylene terephthalate.
[0055] A capsule according to the present invention may be used for packaging concentrated
products (in the form of powder or granules or leaves) in predetermined, single-use
doses, for the impromptu preparation of beverages such as leaf or soluble tea, ground
or instant coffee, herbal teas, milk, chocolate, or other dehydrated and soluble products.
[0056] In the embodiment variant for infusion beverages, shown for example in Fig. 1a, wherein
the substance S is coffee powder which remains as a layer of coffee at the end of
dispensing, the capsule 1 comprises, below the cover 6 and above the substance S,
fastened internally to the cup 2, a containment wall 7, provided with holes adapted
to allow for the passage of the pressurized liquid and to retain the substance S.
The containment wall 7 is generally a micro-perforated film made of polyethylene terephthalate
or a nonwoven fabric (NWF) based on polyethylene terephthalate.
[0057] In the embodiment variant for infusion beverages, wherein the substance S is ground
coffee which remains as a layer of coffee at the end of dispensing, the capsule 1
comprises, below the substance S and above the sealing disc 5, fastened internally
to the cup 2, a filtering wall 8, provided with holes adapted to allow the passage
of the beverage and to hold the substance S. The filtering wall 8 is preferably a
micro-perforated film made of polyethylene terephthalate or a non-woven fabric (NWF)
based on polyethylene terephthalate.
[0058] Advantageously, in the embodiment variant for soluble beverages, shown for example
in Fig. 1b, wherein the substance S is food powder that entirely dissolves during
the preparation of the beverage without leaving any residues or layers inside the
cup 2, the capsule 1, insofar as it is entirely recyclable, may be thrown directly
into a plastics container.
[0059] Innovatively, a capsule for the preparation of infusion or soluble beverages according
to the present invention is of a single-material, made of polyethylene terephthalate,
and is therefore easily recyclable by the consumer and has a low environmental impact,
while ensuring high mechanical strength and high temperatures.
[0060] Advantageously, in one embodiment, the capsule for preparing infusion or soluble
beverages according to the present invention is entirely of a single-material made
of polyethylene terephthalate that is at least partially recycled.
[0061] The capsule, according to the present invention, is advantageously made entirely
of the same material. In particular, the cover and the sealing disc are made of the
same material as the cup on which they are welded, thereby ensuring continuity of
the material within the joined parts and creating a permanent connection which is
not subject to risks of delamination.
[0062] With respect to known capsules composed of different plastics materials or paper
or aluminum bonded materials that are very difficult to separate from each other at
the time of collecting waste, the capsule that is the subject matter of the present
invention is easily recyclable both for the final consumer and for those industries
that decide to invest in green solutions. A capsule made of a plastics single-material
that is not coupled to other elements is easier to recycle and may be converted into
good quality material that may even be reused to create new packaging.
[0063] It is clear that those skilled in the art may make changes to the cup and to the
capsule for preparing infusion or soluble beverages described above, all falling within
the scope of protection as defined by the following claims.
1. A single-material capsule (1) for preparing soluble beverages, consisting of:
- a cup (2) suitable for defining an inner volume (V), wherein a soluble substance
(S) is contained, said cup (2) being provided with:
-- an inlet opening defined by an outwardly protruding edge (4);
-- a bottom (3) with a nozzle defining an outlet opening (31) for dispensing the beverage,
said nozzle comprising an outer portion (310) and an inner portion (313), said inner
portion (313) being provided with connection openings (314) between the inner volume
(V) and the outlet opening (31);
-- an inner base (33) provided with a plurality of vertically protruding ridges, one
of these ridges being a peripheral edge (360);
- a cover (6) fastened to the edge (4) for sealing the cup (2) at the top;
- a sealing disc (5) forming the bottom closure of the capsule (1), engaged inside
the cup (2) at least at the peripheral edge (360);
characterized in that at least 90% thereof is made of: polyethylene terephthalate or polyethylene terephthalate
combined with a material similar to polyethylene terephthalate and recyclable together
with polyethylene terephthalate, and
in that all of the components (2, 5, 6) that comprise the capsule (1) are entirely or predominantly,
made of polyethylene terephthalate.
2. A single-material capsule (1) for preparing infusion beverages, consisting of:
- a cup (2) suitable for defining an inner volume (V) wherein an infusion substance
(S) is contained, said cup (2) being provided with:
-- an inlet opening defined by an outwardly protruding edge (4);
-- a bottom (3) with a nozzle defining an outlet opening (31) for dispensing the beverage,
said nozzle comprising an outer portion (310) and an inner portion (313), said inner
portion (313) being provided with connection openings (314) between the inner volume
(V) and the outlet opening (31);
-- an inner base (33) provided with a plurality of vertically protruding ridges, one
of these ridges being a peripheral edge (360);
- a cover (6) fastened to the edge (4) for sealing the cup (2) at the top;
- a perforated containment wall (7), arranged below the cover (6) and above the substance
(S);
- a sealing disc (5) forming the bottom closure of the capsule (1), fastened inside
the cup (2) at least at the peripheral edge (360);
- a filtering wall (8) arranged below the substance (S) and above the sealing disc
(5);
characterized in that at least 90% thereof is made of:
polyethylene terephthalate or polyethylene terephthalate combined with a material
similar to polyethylene terephthalate and recyclable together with polyethylene terephthalate,
and
in that all of the components (2, 5, 6) that comprise the capsule (1) are entirely or predominantly
made of polyethylene terephthalate.
3. Capsule (1) according to claim 1 or 2, at least 95% thereof being made of: polyethylene
terephthalate or polyethylene terephthalate combined with a material similar to polyethylene
terephthalate and recyclable with polyethylene terephthalate.
4. Capsule (1) according to any one of the preceding claims, wherein the cup (2) is made
of: polyethylene terephthalate (PET), or polyethylene terephthalate (PET) combined
with glycol-modified polyethylene terephthalate (PETG).
5. Capsule (1) according to any one of the preceding claims, wherein the cup (2) is made
of: between 20% and 50% polyethylene terephthalate (PET), the rest being made of glycol-modified
polyethylene terephthalate (PETG).
6. Capsule (1) according to any one of the preceding claims, wherein the cup (2) is at
least partially made of recycled polyethylene terephthalate (r-PET), and wherein the
percentage of recycled polyethylene terephthalate is between 20% and 100% of the total
polyethylene terephthalate.
7. Capsule (1) according to any one of the preceding claims, wherein the cover (6) comprises
an outer barrier layer of metallized polyethylene terephthalate, joined to an inner
welding layer of polyethylene terephthalate.
8. Capsule (1) according to any one of the preceding claims, wherein the sealing disc
(5) comprises an upper barrier layer of polyethylene terephthalate with a barrier
coating, joined to a lower layer of lacquered polyethylene terephthalate.
9. Capsule (1) according to any one of the preceding claims, wherein the disc (5) is
fastened to the peripheral edge (360) in an at least partially yielding manner, so
as to become detached due an increase in pressure inside the volume (V).
10. Capsule (1) according to any one of the preceding claims, wherein the connection openings
(314) are at most six.
11. Capsule (1) according to any one of the preceding claims, wherein, inside the nozzle
there is a pin-shaped flow director (9) with three points (91), each one being triangular
with rounded edges.
12. Capsule (1) according to any one of the preceding claims, wherein the bottom (3) of
the cup (2) is provided with at least ten, preferably twelve, outer reinforcement
flaps (92) with a rounded profile.
13. Capsule (1) according to any one of the preceding claims, wherein the base (33) comprises
a labyrinth portion (320) in the shape of an annular ridge provided with a plurality
of grooves on an upper surface, and wherein the sealing disc (5) is engaged with said
upper surface to close said grooves at the top to form capillary channels.
14. Capsule (1) according to the preceding claim, wherein, between the peripheral edge
(360) and the labyrinth portion (320), the base (33) is provided with a valley (330)
being deeper than the grooves of the labyrinth portion (320).
15. Capsule (1) according to the preceding claim, wherein the labyrinth portion (320)
occupies a portion of the base (33) equal to or smaller than a portion occupied by
the valley (330) when measured radially.