AU2013231178A1

AU2013231178A1 - A disposable capsule for preparing drinks and a relative manufacturing method

Info

Publication number: AU2013231178A1
Application number: AU2013231178A
Authority: AU
Inventors: Pietro Ettami; Franco Magnani; Massimiliano Maini
Original assignee: T M E Srl
Current assignee: Tme - Srl
Priority date: 2013-06-12
Filing date: 2013-09-24
Publication date: 2015-01-22
Also published as: BR102014003452A2; ITRE20130043A1

Abstract

A DISPOSABLE CAPSULE FOR PREPARING DRINKS AND A RELATIVE MANUFACTURING METHOD An embodiment of the invention discloses a disposable capsule for preparing drinks and a manufacturing method therefor, wherein the comprises steps of: predisposing a container (110), substantially cup-shaped and provided with a flat annular flange (120) able to delimit the mouth thereof (115); positioning internally of the container (110) a dose of a food substance (105) able to produce a drink by interaction with a fluid; closing the container (110) with the dose of food substance internally thereof, by application of a covering element (140) on the annular flange (120); cladding at least the cup-shaped part of the container (110) with heat-retractable material that is impermeable to air; at least locally heating the cladding (150) made of heat-retractable material such that it adheres to at least a portion (160) of the container (110).

Description

1 A DISPOSABLE CAPSULE FOR PREPARING DRINKS AND A RELATIVE MANUFACTURING METHOD Field [0001] The present invention relates to single-use disposable capsules for preparing drinks and a method for manufacturing them. In particular, the present invention relates to disposable capsules which are used in association with coffee machines equipped with a boiler, for preparing coffee and/or other hot drinks. Background [0002] As is known, the disposable capsules of the present invention comprise a dose of a food substance, typically in a granular or powder form, which can realise the drink thanks to interaction, for example by infusion, solution or mixing, with a hot fluid such as water or steam which is produced by the coffee machine. [0003] This dose of food substance is contained internally of a throwaway container, substantially cup-shaped, the mouth of which is delimited by an annular flange on which a covering element is applied to close the container, retaining the dose of food substance internally thereof. [0004] In some embodiments, the container is made of a plastic material by means of an injection-moulding process, and is closed by a covering element which can be realised in the form of an aluminium film, a polymer material or a paper that is permeable to liquids, which is glued or heat-welded on the annular flange of the container. [0005] Machines for preparing the drink can comprise means for piercing the closing film and the base of the cladding so as to enable passage of the drink through the contents of the capsule. [0006] In other cases, the containers made by injection moulding can be provided with one or more holes which are realised on the bottom of the cup, directly during the act of moulding. [0007] The presence of these holes and/or a permeable paper covering has the counter indication that is places the internal volume of the capsule in communication with the external 2 environment, causing the loss of flavour and/or deterioration of the organoleptic properties of the food substance contained in the capsule. [0008] These capsules are thus normally packed in a protective atmosphere internally of special sealed envelopes that are impermeable to air. [0009] In other embodiments, these drawbacks have been obviated by realising the container of the capsule and the relative covering via a heat-retracting process starting from a sheet of multilayer polymer material impermeable to air, which carries out what is known as the barrier effect against oxygen, which is rather slim and is pierced only internally of the coffee machine when the coffee is prepared. [0010] In this way, the container realises an effective hermetic barrier which effectively conserves the flavour and the organoleptic qualities of the food substance contained internally of the capsule. [0011] As a counter-indication, the realization of these capsules is rather expensive. Object of the Invention [0012] It is the object of the present invention to substantially overcome or at least ameliorate one or more of the foregoing disadvantages. Summary of Invention [0013] An aspect of the present invention discloses a manufacturing method of disposable capsules for preparing drinks, comprising steps of: predisposing a container substantially cup-shaped and provided with a flat annular flange able to delimit the mouth thereof, positioning internally of the container a dose of a food substance able to produce a drink by interaction with a fluid, - closing the container with the dose of food substance internally thereof, by application of a covering element on the annular flange, cladding at least the cup-shaped part of the container with heat-retractable material that is impermeable to air, 3 at least locally heating the cladding made of heat-retractable material such that it adheres to at least a portion of the container. [0014] The cladding operations of at least the cup-shaped part of the container with a cladding of heat-retractable material, impermeable to air, and at least locally heating the heat-retraction material of the cladding, such as to cause it to adhere to at least a portion of the container can also be carried out before introducing the dose of the food substance (which will go to produce a drink by interaction with a fluid) in the cup of the container. [0015] According to an embodiment of the present invention, the cup-shaped container can be realised using any known means, even of a type which does not in itself guarantee the hermetic sealing of the food substance, as the barrier against the air passage and thus the oxygen passage is effectively realised by the external cladding of heat-retractable material. [0016] In particular, the cup-shaped container can be manufactured using a relatively inexpensive process, for example an injection-moulding process or even simply using a filter paper. [0017] In this way, the disposable containers obtained using the method of the invention are economical, without requiring them to be packed internally of sealed envelopes. [0018] Further, as the cladding of heat-retractable material protects the cup-shaped container from dirt, both during the transport step and during the handling steps of the disposable capsule previous to the preparation of the drink, thus increasing the hygiene of the whole system can be increased. [0019] Still further, the cladding of heat-retractable material can be easily decorated with colours or graphic symbols which can not only supply useful indications about the product, but also increase the aesthetic appeal of the capsule. [0020] In an embodiment of the invention, the cladding made of heat-retractable material can be heated such that it adheres on all the cup-shaped part of the container. [0021] In this way, the cladding is completely adherent to the capsule, improving both the mechanical resistance and the barrier effect against the passage of air.

4 [0022] In other embodiments, the cladding made of heat-retractable material is heated such that it adheres only locally in a zone underlying the annular flange. [0023] The cup-shaped container can thereby also be realised in a yielding material generally unsuitable for supporting the mechanical action of the heat-retraction. [0024] In such cases, the flange and the zones limiting the flange are in fact the only portions of the container that are sufficiently rigid to enable the heat-retractable material to adhere thereto and realise a stable and effective join between the container and the protective cladding. [0025] In an embodiment of the invention, the cladding also clads the annular flange of the container, at least partially covering the flat surface thereof opposite the cup-shaped portion. [0026] In this way the barrier effect is improved and the stability of the connection between the cup-shaped container and the protective cladding surrounding it is also improved. [0027] In a further embodiment of the invention, the cladding made of heat-retractable material is conformed as a hood which is inserted on the cup-shaped portion of the container. [0028] The assembly and joining of the casing of heat-retractable material on the cup-shaped container can thus be simplified. [0029] In a further embodiment of the invention, the cup-shaped portion of the container comprises at least an annular groove. [0030] The heat-retractable material of the cladding, by retracting, can thereby be made to tend to penetrate into the annular groove, advantageously opposing the possibility of accidental peeling away thereof from the cup-shaped portion of the container. [0031] In a further embodiment of the invention, the cladding of heat-retractable material is made of a multilayer polymer material comprising at least a layer of material selected from between polypropylene (PP) and poly vinyl chloride (PVC), and at least a layer of Ethylene vinyl alcohol (EVOH).

5 [0032] By way of example, the cladding made of a heat-retractable material can be realised using a material formed by two superposed layers respective of poly vinyl chloride (PVC) and Ethylene vinyl alcohol (EVOH), or by three superposed layers of polypropylene (PP), Ethylene vinyl alcohol (EVOH) and polypropylene (PP), or by three superposed layers of polyethylene terephthalate (PET), Ethylene vinyl alcohol (EVOH) and polyethylene (PE), or by three superposed layers of polyethylene (PE), Ethylene vinyl alcohol (EVOH) and polyethylene (PE), or by three superposed layers of poly vinyl chloride (PVC), Ethylene vinyl alcohol (EVOH) and polyethylene (PE), or by three superposed layers of poly vinyl chloride (PVC), Ethylene vinyl alcohol (EVOH) and polyethylene terephthalate (PET), or by three superposed layers of poly vinyl chloride (PVC), Ethylene vinyl alcohol (EVOH) and polypropylene (PP). [0033] The same material can be used to create the cover of the capsule joined to the flange, or in the form of a peelable sheet adhering to the cover if made of another material. [0034] Another aspect of the present invention provides a disposable capsule for preparing drinks which can be obtained with the above-described method, and which therefore comprises: a container substantially cup-shaped and provided with a flat annular flange able to delimit the mouth thereof, a dose of a food substance able to produce a drink by interaction with a fluid, which dose is contained internally of the container, a covering element applied on the annular flange, such as to close the container with the dose of the food substance contained therein, a cladding made of a heat-retractable material, which clads at least the cup portion of the container and adheres to at least a portion of the container. [0035] A disposable capsule in an embodiment of the invention can substantially attains the same advantages as the above-delineated method, and in particular the advantage of providing a disposable capsule which can be realised economically and which guarantees an effective hermetic barrier, without requiring packing in sealed envelopes with a protective atmosphere. [0036] Naturally all the aspects of the above-mentioned invention with reference to the manufacturing method are understood to be valid also for the disposable container.

6 [0037] Further characteristics and advantages of the invention will emerge from a reading of the following description provided by way of non-limiting example with the aid of the figures illustrated in the accompanying tables of drawings. Brief Description of Drawings [0038] A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings in which: [0039] Figure 1 is a lateral view of a disposable capsule for preparing a drink according to an embodiment of the invention. [0040] Figure 2 is a view from below of the disposable capsule illustrated in figure 1. [0041] Figure 3 is section III-III of figure 2. [0042] Figure 4 is a section view of the cup-shaped container and the external cladding which form the capsule of figure 1 before assembly. [0043] Figure 5 illustrates the external cladding and the cup-shaped container of figure 4 inserted one in another before heat-retraction. [0044] Figure 6 illustrates the disposable capsule of figure 5 after having carried out the heat retraction step in the ways provided-for by an embodiment of the invention. [0045] Figure 7 illustrates the disposable capsule of figure 5 after having carried out the heat retraction according to another of the ways provided-for by an embodiment of the invention. [0046] Figure 8 is the section of figure 3 relative to a capsule of an alternative embodiment of the invention. Detailed Description of the Invention [0047] The figures illustrate a disposable capsule 100, which can be used in a special coffee machine (not shown), for preparation of coffee or other hot beverages.

7 [0048] As shown in figure 3, the disposable capsule 100 comprises a first dose of a food substance 105, typically in granular or powder form, which is able to make the drink via interaction, for example by infusion, solution or mixing with a hot fluid such as water or steam that is passed through the capsule 100 using suitable means predisposed in the coffee maker. [0049] To contain the dose of food substance 105, the capsule 100 comprises a substantially cup-shaped container 110, i.e. closed laterally and at the bottom thereof, but provided with a mouth 115 at a top thereof. The specific shape of the cup-shaped container 110 can be any, for example, substantially truncoconical as in the figures, or cylindrical, hemispherical or pyramidal. The mouth 115 of the cup-shaped container 110 is delimited by a flat annular flange 120, which projects from the top of the lateral wall 125, extending outwardly with respect to the cavity containing the food substance 105. [0050] In the illustrated embodiment, the cup-shaped container 110 is realised by means of an injection-moulding process of a plastic material, such as polypropylene (PP), polyethylene terephthalate (PET), polyethylene (PE) or polylactic acid (PLA). [0051] With this moulding technique, the cup-shaped container 110 has a relatively large wall thickness making it overall rather rigid. For this reason, a plurality of through-holes 135 can be formed on the bottom wall 130 of the cup-shaped container 110, which holes 135 are sufficiently small to retain the food substance 105, the function of which is to allow passage of water during the preparation of the beverage inside the coffee maker. [0052] Alternatively, the cup-shaped container 110 may be made of a thin material and perforated, for example in the form of a cup-shape of filter paper possibly pleated at the lateral wall 125. [0053] In other embodiments (not illustrated), the cup-shaped container 100 might be realised using a heat-retracting process starting from a sheet of multilayer polymer material, for example formed by three superposed layers of polypropylene (PP), Ethylene vinyl alcohol (EVOH) and polypropylene (PP), or three superposed layers of polyethylene terephthalate (PET), Ethylene vinyl alcohol (EVOH) and polyethylene (PE), or three superposed layers of polyethylene (PE), Ethylene vinyl alcohol (EVOH) and polyethylene (PE).

8 [0054] With this technique of heat-retracting, the cup-shaped container 110 has a relatively-slim wall thickness, of the order of a few tenths of a millimetre, making it generally yielding. For this reason, the cup-shaped container 110 thus-realized can be completely free of holes and be pierced only at the time of preparation of the beverage, by appropriate means for this purpose and installed in the coffee maker. [0055] Independently of the way the cup-shaped container 110 is made, the opening 115 is closed by a covering element 140 applied on the annular flange 120, so as to internally retain the dose of food substance 105. [0056] In the embodiment illustrated in the figures, the covering element 140 can be realized in the form of a thin sheet of permeable material, such as filter paper, or it can be a relatively rigid perforated lid. [0057] In both cases, the covering element 140 can further comprise a film 145 of a multilayered polymer material (for example of the type mentioned herein above), which is made to adhere on sheet of permeable material or the perforated lid. [0058] This film 145 can be peelable, i.e. it can be removed by a peeling action with respect to the annular flange 120 of the container 110 and to the underlying covering element 140. In this way, the film 145 can be removed before inserting the disposable capsule 100 in the coffee machine, in order to allow water and/or steam to wet the food substance 105. [0059] In other embodiments, the covering element 140 can include only the film 145, which can be made to adhere, for example can be glued or welded directly on the annular flange 120 of the cup-shaped container 110. [0060] In this case, the film 145 can be left attached to the annular flange 120 and be perforated only at the time of preparation of the beverage, by appropriate means installed directly in the coffee machine. [0061] Independently of how the container cup 110 and the cover element 140 are made, the disposable capsule 100 comprises an external cladding 150 made of heat-retracting material and impermeable to air, having a barrier effect, which clads the cup-shaped portion of the container 110, or the bottom wall 130 and the lateral wall 125.

9 [0062] The heat-retracting material of the outer casing 150 is preferably a multilayered polymeric material, for example comprising at least one layer of a material selected from polypropylene (PP) and polyvinyl chloride (PVC), and at least one layer, with a barrier effect, of Ethylene vinyl alcohol (EVOH). [0063] By way of example, the external cladding 150 can be made of a heat-retractable material formed by two superposed layers respectively of poly vinyl chloride (PVC) and Ethylene vinyl alcohol (EVOH), or by three superposed layers of polypropylene (PP), Ethylene vinyl alcohol (EVOH) and polypropylene (PP), or by three superposed layers of polyethylene terephthalate (PET), Ethylene vinyl alcohol (EVOH) and polyethylene (PE), or by three superposed layers of polyethylene (PE), Ethylene vinyl alcohol (EVOH) and polyethylene (PE), or by three superposed layers of poly vinyl chloride (PVC), Ethylene vinyl alcohol (EVOH) and polyethylene (PE), or by three superposed layers of poly vinyl chloride (PVC), Ethylene vinyl alcohol (EVOH) and polyethylene terephthalate (PET), or by three superposed layers of poly vinyl chloride (PVC), Ethylene vinyl alcohol (EVOH) and polypropylene (PP). As shown in figure 4, the external casing 150 is realized in the form of a beaker-shaped hood, which is inserted coaxially on the cup-shaped portion of the container 110, up to completely or almost completely containing the container 110, as shown in figure 5. [0064] Once this position is reached, the external casing 150 is suitably heated causing it to contract, up until it stably adheres to the cup-shaped container 110. [0065] In the embodiment illustrated in figure 6, the external casing 150 is heated in its entirety, so that it adheres to all the cup-shaped portion of the container 110. [0066] To improve this join, some annular grooves 155 can be formed on the lateral wall 125 of the cup-shaped container 110, which grooves 155 are arranged coaxially to one another and with the axis of the cup-shaped container 110. In this way, the heat-retracting material of the external casing 150, when retracting, tends to penetrate into these annular grooves 155, creating an interference fit which advantageously opposes all mutual slippage between the external casing 150 and the cup-shaped container 110. [0067] In the embodiment illustrated in figure 7, the external casing 150 is instead only partially heated, in order to adhere only to an annular portion 160 of the cup-shaped container 110, which 10 has a (much) smaller axial extension compared to the total height of the cup-shaped container 110 and is located in proximity of the annular flange 120, preferably immediately below it. [0068] This solution is particularly advantageous when the cup-shaped container 110 is made of a flexible material, such as filter paper, or by heat-retraction, which otherwise might get crushed and/or deformed by a complete contraction of the external cladding 150. [0069] In both the illustrated cases, the external cladding 150 is however permanently joined to the cup-shaped container 110, covering it and serving as an effective hermetic barrier preventing the food substance 105 from coming into contact with the air, thus preserving the flavour and the organoleptic properties. [0070] As illustrated in the embodiment of figure 8, the external cladding 150 can also cover the annular flange 120, at least partially covering the upper surface thereof. [0071] In this case too, during the heat-retraction, the external casing 150 can be completely heated, so that it adheres to all of the cup-shaped portion of the container 110 and to the annular flange 120, or it can be heated only partially, so that it adheres only to the annular flange 120 and possibly to a further portion of the cup-shaped container 110 located immediately below the annular flange 120. In any case, the fact that the external casing 150 surrounds and covers also the annular flange 120 means that the capsule 100 is completely clad by material achieving a barrier effect, and that the cup-shaped container 110 does not necessarily have to be provided with the annular grooves 155. [0072] Before using the disposable capsule 100 in the coffee machine, the external cladding 150 can be removed, for example with the aid of a tear-off tab (not illustrated) with which the external casing 150 can be previously provided. Alternatively, the external cladding 150 can be left attached to the cup-shaped container 110 and be pierced only at the time of preparation of the beverage, by appropriate means for this purpose, and installed directly in the coffee machine. [0073] In conclusion, it is observed that, although an external cladding 150 has been described that surrounds and covers only the portion of the container cup 110 and possibly the flange 120, in other embodiments the cladding 150 made of heat-retracting material could surround and clad the whole capsule 100, including the covering element 140.

11 [0074] Obviously, a technician in the sector might bring numerous modifications of a technical application to the disposable capsule and to the relative manufacturing method described herein above, without forsaking the scope of the invention as claimed in the following.

Claims

1. A manufacturing method of disposable capsules for preparing drinks, comprising steps of: predisposing a container substantially cup-shaped and provided with a flat annular flange able to delimit the mouth thereof, positioning, internally of the container, a dose of a food substance able to produce a drink by interaction with a fluid, closing the container with the dose of food substance internally thereof, by application of a covering element on the annular flange, cladding at least the cup-shaped part of the container with heat-retractable material that is impermeable to air, at least locally heating the cladding made of heat-retractable material such that it adheres to at least a portion of the container.

2. The method of claim 1, wherein the cladding made of heat-retractable material is heated such that it adheres to all the cup-shaped part of the container.

3. The method of claim 1, wherein the cladding made of heat-retractable material is heated such that it adheres to the container only locally in a zone underlying the annular flange.

4. The method of any one of the preceding claims, wherein the cladding also clads the annular flange, at least partially covering the flat surface opposite the cup-shaped portion.

5. The method of any one of the preceding claims, wherein the cladding made of heat retractable material is conformed as a hood which is inserted on the cup-shaped portion of the container.

6. The method of any one of the preceding claims, wherein the cup-shaped portion of the container comprises at least an annular groove.

7. The method of any one of the preceding claims, wherein the cladding made of heat retractable material is made of a multilayer polymer material comprising at least a layer of material selected from between polypropylene (PP) and poly vinyl chloride (PVC), and at least a layer of Ethylene vinyl alcohol (EVOH). 13

8. A disposable capsule for preparing drinks, comprising: a container substantially cup-shaped and provided with a flat annular flange able to delimit the mouth thereof, a dose of a food substance able to produce a drink by interaction with a fluid, which dose is contained internally of the container, a covering element applied on the annular flange, such as to close the container with the dose of the food substance contained therein, and a cladding made of a heat-retractable material, which clads at least the cup-shaped portion of the container and adheres to at least a portion of the container. T.M.E. - S.R.L. Patent Attorneys for the Applicant/Nominated Person SPRUSON & FERGUSON