WO2025082889A1

WO2025082889A1 - Capsule compostable top lid structure, sheet material for making the same and method

Info

Publication number: WO2025082889A1
Application number: PCT/EP2024/078829
Authority: WO
Inventors: Gilles Gerber; Chiara PAVAN
Original assignee: Societe des Produits Nestle SA; Nestle SA
Current assignee: Societe des Produits Nestle SA; Nestle SA
Priority date: 2023-10-17
Filing date: 2024-10-14
Publication date: 2025-04-24
Anticipated expiration: 2026-04-17

Abstract

The invention relates to a sheet material (3) from which at least one delivery wall (300) for closing a chamber (250) of a capsule body (200) of a beverage capsule (100) for preparing a beverage, can be obtained by cutting or punching of the sheet material (3), the delivery wall (300) comprising in a layered manner in the following order: - a carrier layer (320) forming a base layer for carrying subsequent layers, - a barrier layer (340) for providing a preferably bidirectional barrier against moisture and/or gas, the barrier layer (340) being preferably made of a different material than the carrier layer (320); the barrier layer (340) being applied on the carrier layer (320), - an optional protective layer (350) provided on the surface of the barrier layer (340) opposite the carrier layer (320), and - an adhesive layer (330) positioned on the surface of the delivery wall (300) that is oriented towards the chamber (250) for sealing the delivery wall (300) to a rim portion (211) of the capsule body (200), the adhesive layer covering a maximum of 90%, preferably 80%, most preferably 70% of the delivery wall and being at least applied around the perimeter of the delivery wall (300), along its periphery, over a radial distance D comprised between 3 and 12 mm, preferably between 5 and 10 mm, wherein the sheet material (3) comprises cutting area identification means (370, 380) of at least one delivery wall (300) for a cutting device adapted to cut the at least one delivery wall (300) from the sheet material (3). The invention also concerns a method for obtaining, from the sheet material of the invention, at least one delivery wall (300) for closing a chamber (250) of a capsule body (200) of a beverage capsule (100) for preparing a beverage.

Description

CAPSULE COMPOSTABLE TOP LID STRUCTURE, SHEET MATERIAL FOR MAKING THE SAME AND METHOD

Field of the Invention

The invention relates to a sheet material from which at least one delivery wall for closing a chamber of a capsule body of a beverage capsule for preparing a beverage may be obtained and to a method for obtaining at least one delivery wall from said sheet material.

Background

Single-serve beverage capsules for beverage preparation machines are known in the art. These capsules are commonly used for on demand dispensing of beverages, like coffee, tea or hot chocolate, and enjoy popularity due to their fresh tasting, variability of flavors and the convenience of the beverage preparation.

Usually, the capsule containing a beverage component is inserted in a capsule holder of a beverage preparation machine, the capsule holder is closed, and the beverage preparation is started. Fluid, such as water or milk, is delivered to the capsule to interact with the beverage component contained inside the capsule to produce the desired beverage. When a sufficient amount of the fluid fills the capsule, the capsule opens under pressure of the fluid to release the prepared beverage. For example, opening of the capsule can be accomplished by pressing an extraction face of the capsule with a force effected by increasing pressure of the fluid inside the capsule against an opening structure provided in the capsule holder such that the extraction face is torn upon reaching a breaking stress thereof. The opening structure can be a number of relief and recessed elements, e.g., pyramid-like elements, onto which the extraction face extends and tears under the effect of the internal pressure of the fluid. Such pressure-controlled beverage preparation has the advantage that it can produce a beverage of high quality.

However, a high number of parameters and dynamic effects can influence the opening process of the capsule on the extraction face with the aforementioned opening structure and thus, repeatability and consistency in the opening process are difficult to achieve, which may have a negative impact on the result of the finished beverage.

In particular, it has been found that the extraction face needs to show a certain amount of stiffness to ensure pressure built-up in the capsule while avoiding collapse thereof during the opening process. Conversely, the extraction face should be configured such that it can be torn by the opening structure in the opening process. Also, it is desirable that particles and fibers from the beverage component are retained inside the capsule to avoid not only contamination of the prepared beverage but also obstruction of openings in the capsule and/or the opening structure that are provided for dispensing the prepared beverage out of the beverage preparation machine.

In the prior art, these technical challenges are addressed, by forming the extraction face of a membrane made of aluminium with a very precisely controlled thickness, in particular, of about 30 to 40 micrometers. Aluminium offers a number of advantages, such as a high-pressure resistance, durability, flexibility, low weight, provision of long shelf-life and letting the taste of the prepared beverage unaltered. In addition to Aluminium capsules, some consumers are expecting capsules made of alternative material, and in particular capsules made of compostable material.

Therefore, recently various attempts were made to replace Aluminum material used in capsules with alternative materials. For example, bioplastics made from cornstarch or dried pulp made from sugarcane fiber were proposed to be used as capsule materials. However, a disadvantage of such materials is that they do not have the same material properties as presently used materials, like aluminium. For example, capsules made from alternative materials often have a limited shelf-life as they do not provide the same reliable oxygen and moisture barrier as aluminium.

In particular, the design of an extraction face with alternative materials appears to be challenging, as it is not possible to simply transfer the design principles and solutions applied for the former aluminium extraction face to these new materials. Approaches that, for example, simply replace the known aluminium formed extraction face with a paper-based material have proved unsuccessful, because the quality of the prepared beverages, reproducibility of flavors and beverage consistency were not comparable with the high standards set by the known aluminium-based extraction faces.

Additionally, even if some attempts in providing alternative compostable capsules are starting to be successful, the construction, the structure and the design of the capsule top lid membrane (also called delivery membrane or delivery wall) is still a challenge.

This is especially the case as the capsule delivery membrane should be conceived as biodegradable, preferably compostable and should integrate materials allowing for a tight sealing to the capsule rim while still having a structure providing an efficient piercing / opening of the delivery membrane by the opening structure of the beverage preparation machine during the capsule opening process, and an optimized extraction.

A capsule delivery membrane comprising several material layers among which the one positioned on the external surface of the delivery membrane is applied partially, only covering a maximum of 90% of the surface of the delivery membrane, is proposed. The capsule delivery membranes are obtained from cutting of a sheet material, preferably in the form of a laminate. However, due to the fact that one the layer of the delivery membrane is a partial layer, the cutting of the delivery membrane from the sheet material is complexified.

Therefore, it is an object of the present invention to provide a sheet material and method that facilitates the production of such delivery membranes in order to obtain compostable capsules maintaining and/or exceeding the quality and continuity standards of the capsule itself and of the prepared beverage as set by a comparable aluminium capsule.

These and other objects, which become apparent upon reading the description, are solved by the subject-matter of the independent claims. The dependent claims refer to preferred embodiments of the invention.

Summary of the Invention

As used herein, the term "machine" or "device" may refer to an electrically operated device or machine that: can prepare, from a precursor material or ingredient, a beverage and/or foodstuff, or; can prepare, from a pre-precursor material, a precursor material that can be subsequently prepared into a beverage and/or foodstuff. The machine may implement said preparation by one or more of the following processes: dilution; heating; pressurisation; cooling; mixing; whisking; dissolution; soaking; steeping; extraction; conditioning; infusion; grinding, and other like process. The machine may be dimensioned for use on a work top, e.g. it may be less than 70 cm in length, width and height. As used herein, the term "prepare" in respect of a beverage and/or foodstuff may refer to the preparation of at least part of the beverage and/or foodstuff (e.g. a beverage is prepared by said machine in its entirety or part prepared to which the end-user may manually add extra fluid prior to consumption, including milk and/or water). As a preference in the present invention, the beverage extraction device is a Nespresso Original Line extraction machine as described for example in one or more of EP0512468A1, EP0512470A1, EP1654966A1 or EP2142054A1.

The Nespresso® Original Line system when used with capsule made of aluminium, are disclosed along with their opening system, for example, in one or more of EP0512468A1, EP 0512470A1, EP1646305A1 or EP1165398A1. In these references, constructional, manufacturing and/or (beverage) extraction details of such aluminium capsules and/or closing members are also disclosed.

In such system, the capsule is intended to be inserted into an extraction device, in which it can be pierced and injected with a fluid that passes through the bed of coffee contained in the capsule. The capsule is then opened against a supporting part of the device comprising raised elements (in the form of truncated pyramids) under the effect of the pressure of the fluid entering and rising in the capsule.

As used herein, the term "container", "capsule" or "cartridge" may refer to any configuration to contain the precursor material, e.g. as a single-serving, pre-portioned amount. The container may have a maximum capacity such that it can only contain a single serving of precursor material. The container may be single use, e.g. it is physically altered after a preparation process, which can include one or more of: perforation to supply fluid; for example a liquid like water, to the precursor material; perforation to supply the beverage/foodstuff from the container; opening by a user to extract the precursor material. The container may be configured for operation with a container processing unit of the machine, e.g. it may include a flange for alignment and directing the container through or arrangement on said unit. The container may include a rupturing portion, which is arranged to rupture when subject to a particular pressure to deliver the beverage/foodstuff. The container may have a membrane for closing the container. The container may have various forms, including one or more of: frustoconical; cylindrical; disk; hemispherical, and other like form. The container may be formed from various materials, such as metal or plastic or wood pulp based a combination thereof. The material may be selected such that it is: food-safe; it can withstand the pressure and/or temperature of a preparation process. The container may be defined as a capsule, wherein a capsule may have an internal volume of 20 - 100 ml. The capsule includes a coffee capsule, e.g. a Nespresso® Original Line capsule. Alternative capsules like Nespresso® Vertuo Line, Nescafe® Dolce Gusto or other capsule may be also considered.

As used herein, the term "system" or "beverage or foodstuff preparation system" may refer to the combination of any two or more of: the beverage or foodstuff preparation machine; the container; the server system, and the peripheral device.

As used herein, the term "beverage" may refer to any substance capable of being processed to a potable substance, which may be chilled or hot. The beverage may be one or more of: a solid; a liquid; a gel; a paste. The beverage may include one or a combination of: tea; coffee; hot chocolate; milk; cordial; vitamin composition; herbal tea/infusion; infused/flavored water, and other substance. As used herein, the term "foodstuff" may refer to any substance capable of being processed to a nutriment for eating, which may be chilled or hot. The foodstuff may be one or more of: a solid; a liquid; a gel; a paste. The foodstuff may include yoghurt; mousse; parfait; soup; ice cream; sorbet; custard; smoothies; other substance. It will be appreciated that there is a degree of overlap between the definitions of a beverage and foodstuff, e.g. a beverage can also be a foodstuff and thus a machine that is said to prepare a beverage or foodstuff does not preclude the preparation of both.

As used herein, the term "precursor material" or "ingredient" may refer to any material capable of being processed to form part or all of the beverage or foodstuff. The precursor material can be one or more of a: powder; crystalline; liquid; gel; solid, and other. Examples of a beverage forming precursor material include ground coffee; milk powder; tea leaves; coco powder; vitamin composition; herbs, e.g. for forming a herbal/infusion tea; a flavoring, and; other like material. Examples of a foodstuff forming precursor material include dried vegetables or stock as anhydrous soup powder; powdered milk; flour-based powders including custard; powdered yoghurt or ice-cream, and; other like material. A precursor material may also refer to any pre-precursor material capable of being processed to a precursor material as defined above, i.e. any precursor material that can subsequently be processed to a beverage and/or foodstuff. In an example, the pre-precursor material includes coffee beans which can be ground and/or heated (e.g. roasted) to the precursor material.

As used herein, the term "fluid" (in respect of fluid supplied by a fluid conditioning system) may include one or more of a liquid, for example, water; milk; other.

As used therein, the expression "compostable material" may be understood as any material that can be broken down into environmentally innocuous products by (the action of) living things (such as microorganisms, e.g. bacteria, fungi or algae). This process could take place in an environment with the presence of oxygen (aerobic) and/or otherwise without presence of oxygen (anaerobic). This may be understood, for example, as meaning that composting can be carried out without reservation. In particular, at the end of a composting process there are no residues of the material, which may be problematic for the environment, or any non-biodegradable components. International standards, e.g. EU 13432 or US ASTM D6400, specify technical requirements and procedures for determining compostability of a material.

As used herein the term "wood pulp-based" may refer to the material or a portion of material forming the container which is one or more of: porous; fibrous; cellulosic; formed of cellulosic material; formed of natural cellulosic material; formed of reconstituted or regenerated cellulosic material; non-woven; is composed entirely of or is a composition of wood pulp, and is wet formed. A thickness of the wood-based material may be 0.25 mm to 0.75 mm or about 0.5 mm. The wood-based material may be 200-400 gsm.

As used herein the term "non-woven" may refer to a fabric-like material which is not woven or knitted. A non-woven material may be made from bonded together fibres. As used herein the term "porous" may refer to material configured with interstices to transmit water (or other liquid) therethrough. As used herein the term "fibrous" may refer to material comprised of fibers, which may be present in one or more of the material constituents. As used herein the term "cellulosic" or "cellulosic material" may refer to conventionally woody and/or non-woody materials, e. g. manila hemp, sisal, jute, bleached and unbleached soft wood and hard wood species. A cellulosic material may include a regenerated or reconstituted cellulose. As used herein the term "natural cellulosic material" may refer to conventionally woody materials, which are not regenerated. As used herein the term "reconstituted or regenerated cellulosic material" may refer natural cellulosic material subject to processing that comprises reconstitution or regeneration, examples include rayon and lyocell. As used herein the term "wood pulp" may refer to a lignocellulosic fibrous material, which may be prepared by mechanical or chemical separation of cellulose fibers from one or more of wood, fiber crops, paper or rags. As used herein the term "wet formed" may refer to a process of forming from an aqueous solution of fibers. The aqueous solution of fibers may be heated and pressed in a mold to set the material and remove water therefrom.

The capsule of the invention has the same design as a Nespresso® Original Line capsules and is fully made (capsule body and delivery wall) of compostable material, preferably of cellulose-based material, more preferably of pulp-molded cellulose-based material. The capsule is in the form of a frustoconical cup and has for example a diameter of 2 - 5 cm and an axial length of 2 - 4 cm.

A capsule comprising the delivery wall obtained from the sheet material of the invention, and related extraction process is for example disclosed in EP0512468A1, EP 0512470A1, EP1646305A1 or EP1165398A1.

Alternative capsules, like Nespresso® Vertuo Line, and adapted extraction system are for example disclosed in EP 2155021, EP 2316310, EP 2152608, EP2378932, EP2470053, EP2509473, EP2667757 and EP 2528485 in which constructional, manufacturing and/or (beverage) extraction details of containers are disclosed.

In variant embodiments, which are not illustrated: the capsule may have other crosssection shapes, including square, other polygons, or elliptical; the closing member may be rigid or other non-membrane formation; the flange is alternatively connected to the upper surface of the closing member, e.g. by crimping; the sidewall is alternatively arranged, including with the reverse taper or is aligned to the depth direction, or is curved; the base is alternatively arranged, including with as flat or curved; the flange portion is connected to the storage portion rather than being integrally formed; the closing member is arranged as a storage portion, e.g. it comprises a cavity, and; the flange portion is omitted, e.g. the closing member connects directly to the storage portion.

As mentioned, a first aspect of the invention relates to a sheet material from which at least one delivery wall for closing a chamber of a capsule body of a beverage capsule for preparing a beverage, can be obtained. In these respects, the invention provides a sheet material according to Claim 1.

In more details, a capsule may be understood as a receptacle for containing a substance for preparing a beverage and preferably may form a case or container that surrounds the substance comprising a capsule body and a delivery wall.

The capsule body is of a three-dimension shape. It delimits with its sidewall (at least part of) a chamber, which may be a compartment, a cavity or a hollow space in the capsule, for example. The chamber generally contains a beverage or foodstuff ingredient or substance for the preparation of the beverage. The capsule body also comprises a rim portion delimiting an opening in the sidewall. The capsule further comprises an injection wall suitable for injecting a fluid in the chamber. Injection of the fluid may lead to an interaction of the fluid with the substance, which may include any kind of chemical and/or physical reaction between the substance and the fluid, such as wetting, infusion, extraction, dissolution, and/or any other kind of corresponding interaction to produce a beverage product. The capsule is closed by a delivery wall that is connected to the capsule body to close the chamber. For example, it may be conceivable that a space inside the capsule may be (completely) surrounded from all sides by the container body (sidewall), the injection wall and the delivery wall, preferably such that the chamber for receiving the substance is formed (and closed). Thereby, a capsule can be provided that can be filled with a substance for preparing a beverage and used with known capsule machines. The substance can be protected from degradation and outside influences, like oxidation or moisture, and flavours of the substance can be kept inside the capsule even when storing the same for extended periods.

Generally speaking, a sheet material from which at least one delivery wall for closing a beverage capsule is proposed. The delivery wall of the capsule can be obtained by cutting or punching of the sheet material.

The delivery wall obtained from the sheet material, comprises in a layered manner in the following order: a carrier layer forming a base layer for carrying subsequent layers, a barrier layer for providing a preferably bidirectional barrier against moisture and/or gas, the barrier layer being preferably made of a different material than the carrier layer, the barrier layer being applied on the carrier layer, an optional protective layer provided on the surface of the barrier layer opposite the carrier layer, and an adhesive layer positioned on the surface of the delivery wall that is oriented towards the chamber for sealing the delivery wall to a rim portion of the capsule body, the adhesive layer covering a maximum of 90%, preferably 80%, most preferably 70% of the delivery wall and being at least applied around the perimeter of the delivery wall, along its periphery, over a radial distance D comprised between 3 and 12 mm, preferably between 5 and 10 mm.

According to the proposed invention, the sheet material comprises cutting area identification means of at least one delivery for a cutting device adapted to cut the at least one delivery wall from the sheet material. Within the proposed delivery wall of the sheet material, the different layers are ordered in a specific way and the delivery wall comprises in this proposed order a carrier layer, a filter layer, an optional protective layer, and an adhesive layer.

The carrier layer (also called retention layer) of the delivery wall is provided such that it may be opened upon interaction with opening elements (e.g. of the beverage production machine) under the effect of rising pressure of the fluid being injected into the capsule, for example by relative movement between the respective elements. Therein, the opening elements may have various configurations, forms and shapes and may comprise a plurality of relief and recessed elements, e.g. pyramid-like elements. This design allows tailoring the design of the delivery wall to technical needs.

The barrier layer of the delivery wall aims at providing a preferably bidirectional barrier properties against moisture and/or liquid and/or gaseous substance, preferably oxygen, entering and/or leaving the chamber.

The proposed barrier layer extends preferably between the carrier layer and the at least one adhesive layer.

Additionally, the at least one barrier layer is made of a biodegradable and preferably compostable material, such as biopolymers, polyvinyl alcohol (PVOH), Butenediol vinyl alcohol copolymer (BVOH), or polymers or co-polymers where at least one of the monomer units is vinyl alcohol, and compounds or laminates of the above-mentioned materials

Preferably, the barrier layer is preferably made of a different material than the carrier layer as the expected physicochemical properties of the barrier layer is the protection of the substance enclosed in chamber against moisture and/or oxygen and not any filtering or retention properties.

The protective layer of the delivery wall, which is optional, is applied on the carrier layer, for the protection of the barrier layer. It is thereby possible to guarantee that the barrier layer is fully protected.

The at least one protective layer is preferably non hydrosoluble to avoid its degradation by the moisture content of the substance enclosed in the chamber. The protective layer is preferably made of a different material than the carrier layer and the barrier layer to ensure proper separation of the physicochemical properties of the different layers.

The at least one protective layer is made of a biodegradable and preferably compostable material, such as a vegetable-based starch or acrylic adhesive.

The adhesive layer of the delivery wall is applied on the side of the carrier layer that is oriented towards the chamber, and is used for joining, preferably sealing, preferably heatsealing, the delivery wall onto the rim portion of the capsule body. As mentioned, the adhesive layer covers a maximum of 90%, preferably 80%, most preferably 70% of the surface of the delivery wall and is ate least applied around the perimeter of the delivery wall along its periphery over a radial distance D of comprised between 3 mm and 12 mm, preferably between 5 and 10 mm.

Preferably, the adhesive layer covers a maximum of 75% of the surface of the delivery wall, specifically of the carrier layer, more specifically of the protective layer. More preferably, the adhesive layer covers a maximum of 50 %, even more preferably a maximum of 30%, most preferably a maximum of 20% of the surface of the delivery wall, specifically of the carrier layer, more specifically of the protective layer.

The specific location of the adhesive layer, at least all around the perimeter of the carrier layer allows its efficient sealing onto the rim portion of capsule body and its limited extension on the surface of the carrier layer of the delivery wall ensures that the delivery wall will be correctly interacting with the opening elements of the beverage preparation machine without physical and/or chemical interferences.

With the proposed configuration, and especially when the surface of the delivery wall covered by the adhesive layer is low (below 75, preferably below 50% or even 30% of the surface of the carrier layer), opening of the delivery wall is improved and a better and uniform extraction result can be achieved.

On the same way as the carrier layer, the adhesive layer is of a biodegradable and preferably compostable material. For example, the adhesive layer may be a vegetable-based starch or acrylic adhesive.

Preferably, the at least one adhesive layer is made of a different material than the carrier layer / barrier layer. Generally, this may lead to the advantageous effect that the combination of the two or more constituent materials with different physical or chemical properties produce a structure with different and added characteristics coming from each of the individual components.

As claimed, the sheet material comprises cutting area identification means of at least one delivery for a cutting device adapted to cut the at least one delivery wall from the sheet material.

Thanks to the presence of cutting area identification means, it is possible to correctly cut one or more delivery wall from the sheet material, taking into account the presence of the partial adhesive layer which is applied only partially onto the delivery wall and hence on the sheet material.

The cutting area identification means allow a correct positioning of the cutting device vis a vis the sheet material for the cutting of the sheet material to form the delivery wall(s). According to an additional feature, the delivery wall further comprises a filter layer on the surface of the carrier layer opposite the barrier layer, for filtering out particles from the prepared beverage dispensed via the delivery wall.

Hence, the filter layer is provided opposite to the chamber with respect to the carrier layer. Therein, it has surprisingly been found that the particular order and orientation of the carrier layer and the filter layer with respect to the capsule body as defined in the present invention leads to a number of improvements. For example, it is observed that the pressure profile during the beverage preparation is more consistent and reproducible. Moreover, a better crema formation and extraction and a reduced concentration of particles and residues of the substance, e.g. roast and ground of coffee, is found with this configuration in the beverage.

Resulting from the above, the carrier layer may face the chamber or may be provided closer to the chamber than the filter layer. Therein, for example, the expression "facing" may be understood as being directed towards the respective reference object without necessarily having to be provided directly onto the respective reference object.

Each of the filter layer and the carrier layer is made of a biodegradable, preferably compostable material. This may lead to a more straightforward recovery of the organic material inside the capsule as well as of the capsule material itself.

In addition, the delivery wall further comprises a bonding layer at least partially joining the filter layer and the carrier layer to each other on opposite sides thereof, preferably through adhesive bonding or heat-sealing and provided between the carrier layer and the filter layer.

As proposed, the bonding layer is provided between the carrier layer and the filter layer to ensure efficient adhesion of the two above-mentioned layers.

The bonding layer is of a biodegradable and preferably compostable material, such as vegetable-based starch or acrylic adhesive and participate to the biodegradable properties of the complete capsule.

More particularly, with the disclosed delivery wall's structure, the thickness of the sheet material from which at least one delivery wall is obtained, may be comprised between 100 microns and 200 microns, preferably between 120 microns and 180 microns.

From the above, the delivery wall of the sheet material of the invention comprises in a layered manner the filter layer, the bonding layer, the carrier layer, the barrier layer, the protective layer and the adhesive layer. Thus, the delivery wall may comprise different parts that are arranged in plies, slats, tiers or as strata. Thereby, it is possible to provide the delivery wall with an arbitrary number of layers that each can provide a desired functionality, such as, for example, a layer for sealing, (a further layer) for forming a (moisture/gaseous (oxygen)) barrier, and/or for purifying and/or sieving out certain particles or contents from the prepared beverage before the prepared beverage leaves the capsule (the chamber), such as with the filter layer. Therein, the delivery wall may have various (layer) configurations, forms and shapes.

Hence, the delivery wall may comprise any additional layers beside the already disclosed layers, including the filter layer, the carrier layer, and the adhesive layer. These additional layers may be intercalated between the filter layer, carrier and the adhesive layers as needed and depending on their function.

The different layers are preferably made of different materials that preferably distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation.

For instance, by providing at least the aforementioned carrier layer and filter layer from two different materials, it is possible to provide the delivery wall as a composite structure. However, it is also conceivable that the delivery wall may comprise multiple different layers, which preferably may be made from different materials. This may lead to the advantageous effect that the combination of the two or more constituent materials with different physical or chemical properties produce a structure with characteristics different from each of the individual components. Thereby, the interface of the capsule to the outside can be tailored to the technical needs of the application. For example, by providing each of the layers with a different tensile strength, the pressure built up inside the capsule can be controlled and defined as required. Thereby, for example, the capsule can be designed to produce a beverage according to the specifications of its recipe. Moreover, by providing the two layers from materials with a different fiber configuration it is possible to tailor material characteristics relevant for the interaction of the delivery wall with the prepared beverage to the individual application, such as defining the filtering capabilities of the delivery wall. Also, the difference of orientation of the individual layers of the delivery wall may lead to different stresses in the layers, which can be taken into consideration with the above configuration by selecting different materials. Fr example, the material of one of the layers may break at a lower pressure than the material of another layer but the structure may be kept together by the combined resistance of each material, which may support each other under the effect of pressure.

More particularly and in view of the above, the at least one delivery wall of the sheet material may be a laminated layered structure comprising one or more of the carrier layers, the filter layer, the bonding layer, the barrier layer, the protective layer, and the adhesive layer.

The cutting and the handling of the delivery wall for its sealing on the capsule body is made easier with a laminated structure. In case not all of the delivery wall's layers are laminated, the other layers may be coated or applied according to a known method.

In the proposed solution, each layer of the delivery wall formed from the sheet material, is made of biodegradable and/or compostable material and the delivery wall as a whole is also biodegradable and/or compostable.

Preferably, the different layers forming the delivery wall, namely, the filter layer, the bonding layer, the carrier layer, the barrier layer, the protective layer and the adhesive layer, which can be each formed of one or more layers, are made of different biodegradable, preferably compostable, material.

Therein, the expression "biodegradable material" may be understood as any material that can be broken down into environmentally innocuous products by (the action of) living things (such as microorganisms, e.g. bacteria, fungi or algae). This process could take place in an environment with the presence of oxygen (aerobic) and/or otherwise without presence of oxygen (anaerobic). This may be understood, for example, as meaning that composting can be carried out without reservation. In particular, at the end of a composting process there are no residues of the material, which may be problematic for the environment, or any non-biodegradable components.

Examples for biodegradable materials may be different plant-based materials, such as wood, bamboo, bamboo fibers, cellulose, cellulose pulp, wood pulp, sugarcane pulp, paper and/or cardboard. In addition, bioplastic families such as polyhydroxybutyrate (PHB) and co-polymers, polybutylene succinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A/PBSa), polylactide (PLA), polybutylene adipate terephthalate (PBAT), Cellulose Acetate, starch and/or compounds of above mentioned materials are other examples.

International standards, e.g. EU 13432 or US ASTM D6400, specify technical requirements and procedures for determining compostability of a material. Biodegradation can be tested following standards such as ISO 14855, ISO 17556 or ISO 14851. For example, one of the tests requires that - in order to be considered as being "industrially compostable" - at least 90% of the material in question is biologically degraded under controlled conditions in 6 months. Similar tests exist also to enable home composting certification.

In a proposed embodiment, the cutting area identification means comprises an ink layer interposed between two layers of the delivery wall. The ink layer may formalize the cutting area of the sheet material for the cutting device. In this case, the ink layer may extend on the external perimeter of the delivery wall over a distance between 0,1 and 1 mm, thereby forming a cutting area of each of the delivery walls formed on the sheet material.

Hence, in the above proposed solution, the cutting area for cutting at least one delivery wall from the sheet material may be an ink layer forming a circular contouring like a circle.

An important point to be mentioned with the proposed solution is that the cutting is done on interior contouring formed by the ink layer so that once the delivery wall is cut from the sheet material, the delivery wall is void of any ink layer.

Preferably, the ink layer is interposed between the protective layer and the adhesive layer. This solution may be considered as the one having less impact on the production of the delivery wall, however other positioning means may be considered.

Additionally, or as an alternative, the cutting area identification means may further comprise anyone of a perforation, a precut, an embossing element or contouring structure extending on perimeter of the delivery wall.

The perforation, precut, embossing element or contouring structure is preferably applied during application of the adhesive layer.

Similarly, any perforation, precut or embossing element or contouring structure allows implementing precise and accurate cutting of the sheet material to obtain fully operative delivery wall having a complete structure including an adhesive layer partially covering the surface of the delivery wall.

The selection of the cutting area identification means may depend on the sheet material composition, detection and cutting device.

Additionally, or as an alternative, the cutting area identification means further comprises at least one aligning element on at least one edge of the sheet material. The aligning element allows positioning the cutting device or defining an advancing path for the cutting device so that it can proceed to the cutting of at least one delivery wall.

This aligning element may be in the form of a continuous line and/or in the form of a specific marking, for example a eye mark on one edge of the sheet material.

In this respect, the cutting area identification means as above presented may allow the positioning of the cutting device as well as a check of a correct positioning when the cutting device is coupled with a vision system. In the proposed sheet material, two adjacent delivery walls are spaced apart of a distance comprised between 1 mm and 15 mm, depending on the measurement direction. It makes it possible to optimize the number of delivery walls on a given surface of the sheet material.

A further aspect of the present invention relates to a method for obtaining at least one delivery wall for closing a chamber of a capsule body of a beverage capsule for preparing a beverage, wherein the delivery wall is suitable for draining the prepared beverage from the chamber of the capsule towards an outside of the capsule when the capsule is used in the beverage preparation machine, the method comprising the steps of: providing a sheet material as above presented from which a delivery wall can be obtained, aligning the cutting area identification means provided on the sheet material, relative to a cutting device, cutting, by the cutting device, the sheet material with the so aligned cutting area identification means, and moving the sheet material relative to the cutting device intermittently along an advancing path.

The proposed method allows continuous association and alignment between the sheet material and the cutting device with great accuracy. The advancing path makes it possible to have a continuous process for cutting the sheet material and producing delivery wall(s).

By alignment it is meant that the cutting device is positioned in a specific way in reference to the aligning the cutting area identification means provided on the sheet material, relative to a cutting device

For instance, in the proposed method, the corresponding advancing path is the distance between two consecutive delivery wall centers. By way of example, the advancing path may be comprised between 30 mm and 50 mm, preferably between 35 mm and 45 mm.

The advancing path then takes into account the dimensions of the delivery membrane that may vary depending on the type of capsule it should be sealed on.

More particularly, for the implementation of the proposed method, the cutting device comprises a cutting tool for cutting the delivery wall from the sheet material. For example, the cutting tool may be at least one knife, preferably a circular knife.

According to a further feature, when the cutting area identification means comprise a contouring structure extending along the perimeter of the delivery wall, the cutting device cutting the delivery wall along the inner perimeter of the contouring structure and the obtained delivery wall is void of any cutting area identification means.

Specifically, the obtained delivery wall is void of any ink layer or of any perforation, precut, embossing element or contouring structure or of any aligning elements.

Brief description of the Drawings

The invention is further described with reference to the following examples. It will be appreciated that the invention as claimed is not intended to be limited in any way by these examples.

Embodiments of the present invention will now be described, by way of examples, with reference to the accompanying figures in which:

Figure 1 shows a schematic exploded view of a capsule comprising a delivery wall obtained from the sheet material according to an embodiment of the invention.

Figure 2 shows an enlarged schematic cross-section of a section of a beverage container's delivery wall obtained from the sheet material according to an additional proposed embodiment of the delivery membrane.

Figure 3 shows a portion of the sheet material from which two delivery wall presented in figure 1 are obtained.

Figure 4 shows a schematic top view of a sheet material according to the invention seen from the adhesive layer side.

Figure 5 shows a schematic top view of the sheet material of figure 4 once the delivery walls have been cut.

Detailed description

As used in this specification, the words "comprises", "comprising", and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean including, but not limited to. Any reference to prior art documents in this specification is not to be considered as an admission that such prior art is widely known or forms part of the common general knowledge in the field.

Figure 1 shows an exploded view of a capsule 100 for preparing a beverage in a beverage production machine, the capsule comprising a delivery wall obtained from a sheet material according to an embodiment of the present invention, as well as aspects and features of said capsule and related components. Among other elements, Figure 1 shows an embodiment of a delivery wall closing said capsule.

Figure 2, which will be described at the same time shows in schematic cross-section the structure of another proposed delivery wall of the capsule obtained from a sheet material of the proposed invention.

The capsule 100 may have a composite structure and/or may be made from a composite material, which preferably may consist entirely of biodegradable and/or compostable materials.

The capsule 100 comprises a capsule body 200 with a three-dimensional shape with a sidewall 210. The capsule body 200 may have any shape or form, for example the capsule body may be in the form of a cup-shaped body. For example, the capsule body 200 may have a form that is suitable for the capsule 100 being inserted in a capsule holder of a (known) beverage production machine, for example a Nespresso® beverage production machine. The capsule body 200 may have a truncated-, cup- or bowl-shaped form. The capsule body 200 may have a circular cross-section. Thereby, for example, pressure related forces exerting on the capsule body 200 can be absorbed.

The capsule body 200 comprises a sidewall 210. The sidewall 210 delimits a chamber 250 inside the capsule 100. The sidewall 210 may be provided such that it encloses a continuous space inside the capsule body 100. This is shown exemplarily in Figure 1.

The chamber 250 is arranged to receive and store a substance 500 for the preparation of the beverage. Therein, the substance 500 may be any type of (solid, liquid, at least partially soluble and/or percolate-able) matter of a particular or definite chemical constitution. Examples for substances 500 may be roasted ground coffee, instant coffee, tealeaves, syrup concentrate, fruit extract concentrate, a chocolate product, dehydrated edible substances, and/or combinations thereof. Accordingly, examples for beverages that may be prepared may be coffee- or chocolate-based drinks, or other similar types of food. However, the above examples for the substance 500 and beverages are not to be seen as a complete enumeration. Instead, various other examples are conceivable. The capsule body 200 may have an opening 230 to the chamber 250. The opening 230 may be on at least one of the capsule body's 200 opposite ends. For example, the substance 500 may be filled inside the capsule 100 through the opening 230. The substance 500 may fill the chamber 250 entirely. However, there may be a free space between the opening 230 and the filling level of the substance 500, which may be filled with an inert gas for keeping the substance 500 fresh. Preferably, a rim portion 211 of the sidewall 210 may delimit the opening 230. The rim portion 211 may have the form of a flange and extend from the sidewall 210, preferably away from the chamber 250. In operation, the capsule 100 may be placed on the rim portion 211 inside a capsule holder of a beverage production machine.

The sidewall 210 may be provided such that it forms a continuous mantle surface of the capsule body 200. For example, the sidewall 210 may have an inside surface facing the chamber 250 and an outside surface facing away from the chamber 250.

A protective layer 400 for providing a preferably bidirectional barrier against moisture and/or oxygen for the substance 500 may be provided on the capsule body 200 and/or the sidewall 210. In Figure 1, the protective layer 400 is exemplarily illustrated as being provided as a liner on the inside surface of the sidewall 210, which may extend up to and over the rim portion 211. The protective layer 400 may be provided additionally or alternatively on the outside surface of the sidewall 210. Additionally, or alternatively, the protective layer may be provided as a coating having similar barrier properties. Therein, the protective layer 400 may be made of a biodegradable and preferably compostable material, such as biopolymers or bioplastic families such as PHB and co-polymers, PBS, PBS-A, PLA, PBAT, Cellulose Acetate, starch, PVOH, and it may include any polymers or co-polymers where at least one of the monomer units is vinyl alcohol (for example BVOH, Butenediol vinyl alcohol), as well as compounds or laminates of any of the above-mentioned materials. Preferably, the protective layer 400 may be made of a food safe material (FCS, FCMs).

For example, the capsule body 200 may be made of (laminated) (wet/dry) molded pulp fiber. Preferably, the capsule body 200 may be made of a biodegradable and/or compostable material. The capsule body 200 may be made of a food safe material (FCS, FCMs). The capsule body 200 may comprise a layered and/or laminated structure. For example, the capsule body 200 may be relatively stiff or rigid so not to collapse during operation in a beverage production machine or during storage. The layered and/or laminated design may provide the capsule body 200 with additional rigidity and/or stiffness in comparison to other designs. Therein, the molded pulp fiber may be a composite having an additional substrate, such as biodegradable resin, laminated on the capsule body 200. For example, a laminated structure of the capsule body 200 may be created by providing the protective layer 400 thereon. However, it is also conceivable that the capsule body 200 may comprise, for example, in addition to the protective layer 400 a further laminate film or layer. Alternatively, the capsule body 200 may be made of paper-based material or of a paper-based material with a laminate, specifically shaped to delimit a chamber 250.

The capsule 100 comprises an injection wall 220 for injecting a fluid in the chamber 250 for preparing the beverage upon interaction of the fluid with the substance 500. This is exemplarily illustrated in Figure 1.

The injection wall 220 may be provided on an opposite end of the capsule body 200 to the opening 230. The injection wall 220 may be provided integrally or separately with the capsule body 200. Hence, the capsule body 200 and the injection wall 220 may be made up of separate pieces or may be integrally formed as a one-piece. The injection wall 220 may form a tapered end portion of the capsule body 200. The injection wall 220 may be configured to be perforated by blades of the coffee production machine such that the blades provide openings for the fluid injection. Preferably, the fluid may be a liquid or a liq uid/gas mixture, such as water or milk. As the capsule body 200, the injection wall 220 may comprise also the above-described protective layer 400. It is also conceivable, that the injection wall 220 may comprise (small) openings through which blades of the coffee production machine can enter and pierce the protective layer 400. Like the capsule body 200, the injection wall 220 may comprise a layered and/or laminated structure and may be made of (laminated) molded pulp fiber and/or a food safe material (FCS, FCMs).

The capsule body 200 and the injection wall 220 may be provided such that the chamber 250 is closed (sealed) preferably from at least three sides as shown in Figure 1. The capsule body 200 and the injection wall 220 may be provided such that the injected fluid is dispersed evenly in the chamber 250 along the sidewall 210.

The capsule 100 comprises a delivery wall 300, which is connected to the capsule body 200 to close the chamber 250. This is exemplarily indicated in Figure 1.

The delivery wall 300 is also provided in a layered manner as exemplarily shown in Figure 2.

The delivery wall 300 of Figures 1 and 2 which are two examples of possible delivery walls obtained from sheet materials according to the invention, will be described concurrently.

The delivery wall 300 is flat. The word "flat" shall mean that the delivery wall 300 extends substantially in one plane. In other words, the delivery wall 300 extends in one plane, but it can be deformed in a convex or concave plane, depending on the relative pressure between the inside and the outside of the capsule. In particular, it can happen that the ingredient contained therein (e.g., roast and ground coffee) will produce gases such as carbon dioxide over the storage period of the pod. In this case, an overpressure can be created within the capsule, which forces the - initially flat - delivery wall to bulge outside. It can also happen that the atmospheric pressure varies around the capsule, for instance if the capsule is formed, filled and sealed at a factory which is near sea level, and then said capsule is transported at a higher altitude, where the atmospheric pressure is lower. In such case, the - initially flat - delivery will deflect inwardly in a concave shape.

There is no limitation on the number of (different) layers the delivery wall 300 may have and hence multiple delivery wall arrangement may be proposed.

In the framework of Figure 1, the delivery wall 300 comprises a carrier layer, a barrier layer, a protective layer, an ink layer forming cu and a partial adhesive layer.

In Figure 2, the delivery wall 300 is presented as comprising a filter layer, a bonding layer, a carrier layer, a barrier layer, a protective layer and an adhesive layer.

Each of the above-mentioned layers is preferably made of a different biodegradable and preferably compostable material, wherein preferably the different materials distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation. This principle allows taking advantage of the properties of each layer as well as taking advantage of a combination of these properties.

As mentioned, the delivery wall 300 comprises a carrier layer 320 which may be a film, membrane or ply with a defined thickness and preferably with a substantially planar surface.

In accordance with the use of the capsule in a beverage preparation machine capable of feeding an amount of a fluid under pressure into the capsule, the carrier layer 320, preferably the material of the carrier layer, is configured such that it is resilient against a built-up pressure in the chamber 250 within a given pressure range while still being adapted to be opened under the effect of rising pressure of the fluid being injected in the capsule 100 when the pressure exceeds a certain threshold. For example, the carrier layer 320 may be resilient against a built-up pressure in the chamber that is comprised between 1 and 20 bar, more preferred between 10 and 20 bar, most preferred between 12 and 18 bar.

Therein, the thickness and density of the material may influence the stiffness, i.e., the resistance to a bend, of the carrier layer 320. The carrier layer 320 may have a thickness of material of 10 to 150 micrometers, preferably 30 to 70 micrometers. Preferably, the carrier layer 320 may be attached to the (rim portion 211) capsule body 200, preferably by heatsealing or adhesive bonding. The carrier layer 320 is made of biodegradable material. Preferably, the carrier layer 320 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also.

In the proposed embodiment, the carrier layer 320 is made of a material that has a defined, preferably closed fiber structure, such as fiber structures with at least 50% of weight corresponding to softwood pulp, cellulose fibers, or paper. In a preferred solution, the carrier layer is made of paper-based material.

When the carrier layer is cellulose based, it may have a grammage comprised between 20 and 150 g/m2, preferably between 30 and 100 g/m2.

As an alternative, the closed fiber structure may correspond to Polyhydroxyalkanoate (PHA), Polyhydroxybutyrate (PHB) and co-polymers, Polybutylenesuccinate (PBS/PBS-A), biopolyesters, Cellulose Acetate, starch, polyvinyl alcohol (PVOH), polymers or co-polymers where at least one of the monomer units is vinyl alcohol, compounds and/or laminates of the above-mentioned materials.

According to the needs, the characteristics of the carrier layer can be adjusted. For example, the tensile strength of the carrier layer can be improved by increasing the grammage of its material.

As presented in Figures 1 and 2, the delivery wall 300 also comprises a barrier layer 340 which provides a barrier against moisture and/or oxygen. The barrier is chosen to be a bidirectional barrier against moisture and oxygen to preserve the substance 500, preferably roast and ground coffee, from the moisture and oxygen present outside the capsule. The bidirectional barrier layer 340 acts against liquid and/or gaseous substances/contents entering or leaving the chamber 250. With such an arrangement, the substance 500 keeps its initial quality and does not alter over time.

The barrier layer 340 is positioned on the side of the carrier layer 320 facing the capsule opening 230. It is indeed positioned closest to the opening 230 of the capsule so as to allow keeping all the nutritional properties and aromas of the substance 500.

The barrier layer 340 may be provided in the form of a single layer or in the form of multiple layers and its total thickness may vary between 1 micrometer and 10 micrometers. The amount of barrier material in the one or more barrier layers 340 is comprised between 0,1 to 10 gsm (g/m2), preferably between 1,5 to 4 gsm (g/m2) allowing an efficient barrier to oxygen, for example. The barrier layer 340 is furthermore applied on the surface of the carrier layer 320 that is facing the capsule chamber 250 when the delivery wall 300 is sealed onto the capsule body 200, and said surface has a surface roughness lower than 1;3 microns when measured according to ISO 3274. It is made of a biodegradable (preferably compostable material) such as biopolymers, polyvinyl alcohol (PVOH) or copolymers, or butanediol vinyl alcohol co-polymer (BVOH) or any polymers or co-polymers where at least one of the monomer units is vinyl alcohol, and compounds or laminates of the above-mentioned materials.

In the present case, the barrier layer is made of BVOH (Butenediol vinyl alcohol copolymer) or co-polymer. The barrier layer has a total thickness between 3 and 4 microns.

The delivery walls 300 of Figures 1 and 2 further comprise a protective layer 350 in the form of a protective lacquer. As shown, the protective layer 350 extends on the side of the barrier layer 340 opposite the carrier layer 320 (i.e. facing the chamber 250 of the capsule body 200 when the delivery wall is attached to the capsule body).

This protective layer 350 aims at protecting the barrier layer 340 against moisture. It may be applied in one or more layers in a total amount of 0.1 to 10 gsm with a maximum total thickness of 10 microns.

The protective layer 350 may be made from a material that is preferably nonhydrosoluble and is made of a biodegradable and preferably compostable material, such as acrylic polymers.

The protective layer may be optional.

As can be seen in the Figures, the delivery wall 300 further comprises an adhesive layer 330 for adhesion of the delivery wall 300 to the capsule body 200. As mentioned, and as a one-piece element, the delivery wall 300 may be connected to the rim portion 211 of the capsule body 200 to close the chamber 250, thereby forming a closed capsule 100. This may be accomplished, for example, by heat-sealing or adhesive connection. Therefore, the adhesive layer 330 may be provided (as part of the delivery wall) between the delivery wall 300 and the capsule body 200, with which (adhesive layer) the capsule body 200 and the delivery wall 300 may be attached (joined) to each other.

More precisely and as represented in Figure 1 or 2, the adhesive layer 330 is provided on the protective layer 350., on the side facing the capsule chamber (when the delivery wall is arranged on the capsule boy 200).

The adhesive layer 330 may comprise of one or more adhesive layers 330a, 330b ..., as shown in Figure 2 and may be integrated in the delivery wall 300, especially if integrated into a laminated structure. The total thickness of the adhesive layer 330, applied in one or more layers 330a, 330b, is between 1 and 30 micrometers, preferably between 10 and 15 micrometers. In the proposed embodiment, the thickness is around 10 to 13 micrometers.

The material forming of the adhesive layer may be a biodegradable (and preferably compostable) material, such as vegetable-based starch or acrylic adhesive. In the present embodiment the adhesive layer 330 is a polymer made of acrylic adhesive.

From the above description, the adhesive layer 330 is hence made of a different material than the filter layer 310 and/or the carrier layer 320.

This material of the adhesive layer is preferably hydrophobic.

Additionally, the selected material is non-hydrosoluble to avoid any interaction with / degradation by the moisture content of the beverage substance 500 which may be, for example, roast and ground coffee.

This material is applied, as previously mentioned, in one or more layers. The total amount of adhesive material applied on the perimeter of the carrier layer is comprised between 0,5 and 20 gsm. This ensures that sufficient adhesive material is applied on the carrier layer 320 for an efficient tight sealing of delivery wall 300 on the rim portion 211 of the capsule body 200.

The one or more adhesive layer may be applied as coating, for example, a waterbased coating.

As can be seen in Figure 2, the adhesive layer 330 does not cover the full surface of the delivery wall 300. The adhesive layer has a limited radial extension (starting from the periphery of the delivery wall) and extends solely on the periphery of the carrier layer, all around its perimeter. The extension of the adhesive layer 330 on the perimeter of the carrier layer 320 over at least a radial distance D.

The radial distance D has to be at least equal, preferably a bit bigger than the radial extension of the rim portion 211 on which the delivery wall 300 is sealed. In the proposed embodiment of Figure 4, the radial distance D of extension of the adhesive layer is comprised between 3 mm and 12 mm, preferably between 5 to 10 mm, so that a proper sealing of the periphery of the carrier layer on the rim portion 211 is provided.

Additionally, it can be proposed that the maximum coverage percentage of the surface of the carrier layer by the adhesive layer is 90%, preferably 80%, most preferably below 70%.

In the proposed embodiment, the adhesive layer 330 clearly covers less than 50% of the surface of the carrier layer. As shown in figure 2, the (one or more) adhesive layer 330 (330a, 330b) is only applied on the periphery of the carrier layer 320, all around its perimeter over a radial distance D of about 7 mm. This radial distance D may vary between 3 and 12 mm, however, it is preferably limited in extension to a value that is slightly more than the rim portion radial extension. As exemplified, there is no adhesive layer at the center of the carrier layer to enable easier opening of delivery wall 300 on the opening elements of a beverage production machine.

The surface of the carrier layer 320 covered by the adhesive layer 330 may be limited to the periphery of the delivery wall with an extension of a radial distance D from the perimeter edge of the carrier layer 320 of the delivery wall 300. However, other valuable configurations may be implemented.

In the proposed embodiments, the adhesive layer is a heat-sealing layer 330 that can be sealed on the rim portion 211 by local heat application. The sealing of the delivery wall 300 on the rim portion of the capsule 100 is done all around the perimeter of the delivery wall.

As presented, the adhesive layer may be applied in one or more layers with a total grammage of the adhesive layer(s) comprised between 0.5 to 20 g/m2 to provide sufficient adhesive material for a complete adhesion/sealing of the (periphery of the) delivery wall on the capsule rim portion. Generally, the adhesive layer(s) has a total thickness comprised between 1 and 30 micrometers, preferably between 10 and 15 micrometers.

The direct interaction of the carrier layer (and subsequent layers) with the opening elements with limited presence of the adhesive layer allows for a more effective opening of the carrier layer by the opening elements.

The limitation of the adhesive layer onto the surface of the carrier layer allows for an improved controlled interaction of the delivery wall with the opening elements of the beverage preparation machine.

With the proposed configuration, and especially when the surface of the delivery wall covered by the adhesive layer is low (for example below 50% of the surface of the carrier layer/protective layer), opening of the delivery wall is improved and a better and uniform extraction result can be achieved.

As mentioned, the surface of the delivery wall (or carrier layer) covered by the adhesive layer is preferably be limited to the periphery/perimeter of the delivery wall (or carrier layer) with a radial extension comprised between 3 mm to 12 mm from the perimeter edge of the delivery wall (or carrier layer). The limitation of extension of the adhesive layer to the perimeter of the delivery wall participates in improving the opening of the delivery wall of the capsule when it is used in a beverage preparation machine as previously mentioned.

In a preferred feature, the at least one adhesive layer is hydrophobic.

Additionally, the adhesive layer is non-hydrosoluble to avoid any interaction with the moisture content of the beverage substance. Indeed, the beverage substance that is preferably roast and ground coffee has a resulting moisture content comprised between 2 and 4% and it is mandatory to avoid that this moisture reacts and degrades the adhesive layer. In this way, the adhesive layer is kept integral.

Figure 2 shows in cross section a delivery wall according to Figure 1 to which has been added a filter layer 310 on the side of the carrier layer 320 opposite the barrier layer 340.

The filter layer 310 may be configured to filter out particles from the prepared beverage before dispensing the same via (from) the delivery wall 300. The filter layer 310 may be a film, membrane or ply of a defined thickness (and/or with a (largely) planar surface).

The filter layer 310 is made of biodegradable material. Preferably, the filter layer 310 may be made of a material that is compostable and/or a food safe material (FCS, FCMs) also. For example, the filter layer 310 may be a non-woven material, such as cellulose fibers or PLA. Further examples may be cellulose fibers, wood pulp, sugarcane pulp, rayon fibers, PBS, PBS-A, PHB and/or PLA.

The mechanical and filtering properties of the filter layer 310 may be influenced by the thickness of the material, its density as well as its permeability for particles. The filter layer 310 may have a thickness of material of 10 to 300 micrometers, preferably 30 to 250 micrometers. Additionally, or alternatively, the filter layer 310 may have a grammage between 10 and 200 gm (g/m2), preferably between 20 and 150 gsm (g/m2).

With the proposed delivery wall embodiment, the carrier layer 320 and the filter layer 310 are provided on the capsule body 200 such that the filter layer 310 is provided opposite to the chamber 250 with respect to the carrier layer 320.

Preferably, the carrier layer 320 may face the chamber 250. Alternatively, or additionally, the carrier layer 320 may be provided in the delivery wall closer to the chamber 250 than the filter layer 310. This is exemplarily illustrated in Figure 2.

Preferably, each of the filter layer 310 and the carrier layer 320 may be made of a different biodegradable and preferably also compostable material. The different materials of the two layers may distinguish in at least one of their respective physical properties, such as tensile strength, ductility, elasticity, puncture resistance, density, porosity, and/or, if applicable, fiber structure and/or fiber orientation. For example, it may be preferred that the elasticity of the filter layer 310 may be higher than the elasticity of the carrier layer 320, as, as typical for layered structures, layers being further away from the base layer undergo larger strain during bending compared to layers being closer thereto.

The delivery wall 300 may be provided opposite to the injection wall 220 with respect to the chamber 250. The delivery wall 300 and the injection wall 220 may be provided with respect to each other such that in operation the injected fluid traverses the capsule 100 in the order of the injection wall 220, the chamber 250 (and, if available, the substance 500 contained therein), and the delivery wall 300. The chamber 250 may be fully enclosed by the delivery wall 300 (on one end), the injection wall 220 (on an opposite end thereof) and the sidewall 210 (along/surrounding the sides between the two opposite ends). The delivery wall 300 preferably entirely extends over the opening 230 overlaps (with) the rim portion 211.

According to a further possible feature, the filter layer is made of a compostable and/or non-woven material, such as wood or sugarcane pulp, cellulose fibers, rayon fibers, polybutylene succinate (PBS), poly(butylene succinate-co-butylene adipate) (PBS-A/PBSa), polyhydroxybutyrate (PHB) and/or Polylactic acid (PLA), and/or wherein the filter layer (310) has a grammage between 10 and 150 g/m2, preferably between 20 and 100 g/m2.

Having a filter layer with a grammage between 10 and 150 g/m2, preferably between 20 and 100 g/m2 allows ensuring efficient filtering of any particle of the substance enclosed in the capsule chamber, for example roast and ground coffee.

Thereby, the characteristics of the filter layer can be set by defining their area density of material, i.e. as mass per unit of area. For example, the tensile strength of the filter layer can be improved by increasing the grammage of its material and/or by using a (non-woven) material comprising fibers of a defined length and/or with a defined fibre bonding.

Moreover, the filtration capacity and/or the porosity of the filter layer can be modified, e.g. reduced to smaller particle diameters, by setting the filter layer's material characteristics accordingly. Thereby, it is possible to tailor the filter layer to the specific requirements of the beverage preparation.

In addition, and as proposed in Figure 2, a bonding layer 360 is interposed between the carrier layer 320 and the filter layer 310 to join them through adhesive bonding or heatsealing.

Hence, the carrier layer 320 and the filter layer 310 are at least partially joined to each other on opposite sides thereof, i.e. on their sides facing each other thanks to the bonding layer 360. The bonding layer 360 is made of one or more bonding layers and provides adhesive bonding between the carrier layer 320 and the filter layer 310 to ensure efficient adhesion of the two above-mentioned layers.

The bonding layer is also of a biodegradable and preferably compostable material, such as vegetable-based starch or acrylic adhesive and participate to the biodegradable properties of the complete capsule.

Bonding strength of the bonding layer 360 may vary depending on the material of the filter layer 310 and carrier layer 320.

The proposed delivery walls obtained from the sheet material are in the present case laminated layered structures comprising one or more of the above presented layers.

The sheet material of the invention is hence proposed in the form of a laminated blank comprising the above-described layered structure.

Figure 3 shows a portion of the sheet material 3 from which two similar delivery walls 300 and 300' corresponding to the one disclosed in connection with figure 1 are obtained.

The sheet material 3 has a thickness varying between 100 and 200 microns depending on the number of layers of the delivery walls. Preferably the thickness of the sheet material is comprised between 120 and 180 microns.

The delivery walls 300 and 300' both extend between two dash lines representing a cutting area 375 of the sheet material 3 from which the delivery walls 300 and 300' are obtained.

The presented cross section shows the laminated sheet material 3 comprising a carrier layer 320, a barrier layer 340, a protective layer 350 and an adhesive layer 330. In the proposed figure 3, the adhesive layer 330 comprises two layers 330a and 330b and the two adhesive layers 330a and 330b are partially covering the delivery wall 300.

As visible, figure 3 is presenting, in addition to the material layers of the delivery wall 300 of figure 1, a cutting area identification means 370. As proposed the cutting area identification means is in the form of an ink layer 370. The ink layer 370, similarly as the adhesive layers 330a and 330b, is partial and does not cover the entire surface of the delivery walls 300 and 300'. In the presently proposed arrangement, the ink layer 370 is interposed between the protective layer 350 and one adhesive layer 330b. This specific superposition of the different layers alternating partial adhesive layer 330 and partial ink layer 370 is managed during the production of the sheet material 3.

As will be understood, the cutting device (not represented) used for cutting the delivery walls 300 and 300' from the sheet material 3, will use the ink layer 370 as a cutting area identification mean for positioning a cutting tool that will cut the delivery walls 300 and 300'.

The cutting tool may comprise cutting knives. The shape, size and dimension of the cutting knives will be selected according to the characteristics of the sheet material to be cut.

In the present case, the cutting area 375 is smaller than the complete extension of the adhesive layer 330a to ensure that once the delivery walls 300 and 300' are cut from the sheet material 3, the delivery walls are void of any ink material forming the ink layer 370.

Figure 4 and 5 which will be described jointly are presenting schematic top views of a sheet material seen from the adhesive layer side respectively before and after the delivery walls have been cut.

The sheet material 3 comprises multiples delivery walls 300. The delivery walls are identified as 300 and 300' to differentiate them in the disclosure of the figures, however the delivery walls 300 of one sheet material 3 have preferably the same structure (number of layers and thickness) as being formed from the same sheet material.

The distance between two adjacent delivery walls 300, 300' is comprised between 1mm and 15 mm depending on their layout and the distance between two consecutive delivery wall centers is comprised between 30 mm and 50 mm, preferably between 35 mm and 45 mm.

As can be seen in figure 4, the sheet material 3 is partially covered by the adhesive layer 330 (or by at least one of the adhesive layers), the adhesive layer being represented by hatchings. At the location of the delivery walls 300, 300'... there is no adhesive layer 300 (or at least no external adhesive layer) and an ink contouring 370a formed by the ink layer 370 is visible.

In addition to the ink contouring 370a, one or more additional cutting zone identification means may be added. For instance, in the present embodiment, two additional cutting zone identification means are represented. One is in the form of an eye mark 380 1 positioned on the edge 4 of the sheet material 3 and one is in the form of an aligning line 390.

The eye mark 380 may be used as an advancing path AP for the cutting device. In the present case, the advancing path AP corresponds to the distance between two consecutive delivery wall centers and is comprised between 30 mm and 50 mm, preferably between 35 mm and 45 mm.

The aligning line 390 may be used as a guiding line to avoid any deviation between the cutting device and the sheet material 3.

The plurality of cutting zone identification means may be combined to increase precision of the cutting and/or to control the positioning of the cutting tool. A vision system may be further combined to the cutting device.

In figure 5, the delivery walls 300, 300'... have been cut and as visible the remaining sheet material 3 (with the holes corresponding to the cut delivery walls) still holds the ink contouring 370a such that the delivery walls that have been cut are void of any ink (layer).

The other cutting zone identification means are also still hold by the sheet material 3.

As disclosed in connection with the previously described figures, a method for obtaining at least one delivery wall from a sheet material is proposed.

Once the sheet material 3 from which the delivery walls 300 can be obtained is provided, on a cutting module, a step of aligning the cutting area identification means 270, 380, 390 of the sheet material 3, relative to a cutting device of the cutting module is done.

Thanks to the so aligned cutting area identification means 270, 380, 390, the cutting of the delivery walls from the sheet material 3 is made.

The final step consists of moving the sheet material 3 relative to the cutting device intermittently along an advancing path AP so that the cutting of additional delivery wall may take place.

The cutting module may integrate a vision system to align with one or more of the cutting area identifications means, to increase precision of the cutting and/or to control the positioning of a cutting tool of the cutting device.

The cutting tool preferably comprises at least one knife, for cutting the delivery wall from the sheet material. As disclosed, the shape, size and dimension of the cutting knives are selected according to the characteristics of the sheet material to be cut. As mentioned, in the present embodiment, the advancing path AP corresponds to the distance between two consecutive delivery wall centers which is comprised between 30 mm and 50 mm, preferably between 35 mm and 45 mm.

Furthermore, as explained in connection with figure 5, when the cutting area identification means comprise a contouring structure extending along the perimeter of the delivery wall, for example made from an ink layer integrated in the sheet material structure, the cutting device cuts the delivery wall(s) on the inner perimeter of the contouring structure such that the obtained delivery wall(s) is/are void of any cutting area identification means.

The same applies for the other cutting area identification means that remain onto the sheet material once the delivery walls have been cut from said sheet material.

The proposed arrangement is only exemplary, additional or alternative options exists especially concerning the number of layers, the extension of the adhesive layers and the number and structure of the cutting zone identification means ....

Although the invention has been described by way of example, it should be appreciated that variations and modifications may be made without departing from the scope of the invention as defined in the claims. Furthermore, where known equivalents exist to specific features, such equivalents are incorporated as if specifically referred in this specification.

Claims

1. Sheet material (3) from which at least one delivery wall (300) for closing a chamber (250) of a capsule body (200) of a beverage capsule (100) for preparing a beverage, can be obtained by cutting or punching of the sheet material (3), the delivery wall (300) comprising in a layered manner in the following order: a carrier layer (320) forming a base layer for carrying subsequent layers, a barrier layer (340) for providing a preferably bidirectional barrier against moisture and/or gas, the barrier layer (340) being preferably made of a different material than the carrier layer (320); the barrier layer (340) being applied on the carrier layer (320), an optional protective layer (350) provided on the surface of the barrier layer (340) opposite the carrier layer (320), and an adhesive layer (330) positioned on the surface of the delivery wall (300) that is oriented towards the chamber (250) for sealing the delivery wall (300) to a rim portion (211) of the capsule body (200), the adhesive layer covering a maximum of 90%, preferably 80%, most preferably 70% of the delivery wall and being at least applied around the perimeter of the delivery wall (300), along its periphery, over a radial distance D comprised between 3 and 12 mm, preferably between 5 and 10 mm, wherein the sheet material (3) comprises cutting area identification means (370, 380) of at least one delivery wall (300) for a cutting device adapted to cut the at least one delivery wall (300) from the sheet material (3).

2. Sheet material (3) according to claim 1, wherein the delivery wall further comprises a filter layer (310) on the surface of the carrier layer (320) opposite the barrier layer (340), for filtering out particles from the prepared beverage dispensed via the delivery wall (300).

3. Sheet material (3) according to claim 1 or 2, wherein the delivery wall further comprises a bonding layer (360) at least partially joining the filter layer (310) and the carrier layer (320) to each other on opposite sides thereof, preferably through adhesive bonding or heat-sealing and provided between the carrier layer (320) and the filter layer (310).

4. Sheet material (3) according to anyone of the preceding claims, wherein the at least one delivery wall (300) of the sheet material (3) is a laminated layered structure comprising one or more of the carrier layers (320), the filter layer (310), the bonding layer (360), the barrier layer (340), the protective layer (350) and the adhesive layer (330).

5. Sheet material (3) according to anyone of the preceding claims, wherein each layer of the delivery wall (300) is made of biodegradable and/or compostable material and te delivery wall as a whole is biodegradable and/or compostable.

6. Sheet material (3) according to anyone of the preceding claims, wherein the thickness of the sheet material (3) is comprised between 100 microns and 200 microns, preferably between 120 microns and 180 microns.

7. Sheet material (3) according to anyone of the preceding claims, wherein the cutting area identification means comprises an ink layer (370) interposed between two layers of the delivery wall (300), preferably between the protective layer (350) and the adhesive layer (330); the ink layer extending on the external perimeter of the delivery wall (300) over a distance between 0,1 and 1 mm, forming a cutting area (375).

8. Sheet material (3) according to claim 7, wherein the cutting area (375) for cutting at least one delivery wall (300) from the sheet material is a circular contouring formed by the ink layer (370).

9. Sheet material (3) according to anyone of the preceding claims, wherein the cutting area identification means further comprises anyone of a perforation, a precut, an embossing element or contouring structure extending on the perimeter of the delivery wall (300), preferably applied during application of the adhesive layer (330).

10. Sheet material (3) according to anyone of the preceding claims, wherein cutting area identification means further comprises at least one aligning element (380) positioned on at least one edge (4) of the sheet material (3).

11. Sheet material (3) according to anyone of the preceding claims, wherein two adjacent delivery walls (300) of the sheet material (3) are spaced apart of a distance comprised between 1 mm and 15 mm

12. A method for obtaining at least one delivery wall (300) for closing a chamber (250) of a capsule body (200) of a beverage capsule (100) for preparing a beverage, wherein the delivery wall (300) is suitable for draining the prepared beverage from the chamber (250) of the capsule (100) towards an outside of the capsule (100) when the capsule (100) is used in the beverage preparation machine, wherein the method comprises the steps of: providing a sheet material (3) according to claims 1 to 11 from which the delivery wall (300) can be obtained, aligning the cutting area identification means (370) provided on the sheet material (3), relative to a cutting device, cutting, by the cutting device, the sheet material (3) with the so aligned cutting area identification means, and moving the sheet material (3) relative to the cutting device intermittently along an advancing path (AP).

13. A method according to claim 12, wherein the advancing path (AP) corresponds to the distance between two consecutive delivery wall centers and wherein the advancing path (AP) is comprised between 30 mm and 50 mm, preferably between 35 mm and 45 mm.

14. The method according to any one of claims 12 or 13, wherein the cutting device comprises a cutting tool, preferably at least one knife, for cutting the delivery wall from the sheet material.

15. The method according to claim 12 or 13, wherein, when the cutting area identification means comprise a contouring structure extending along the perimeter of the delivery wall, the cutting device cutting the delivery wall on the inner perimeter of the contouring structure and the obtained delivery wall (300) is void of any cutting area identification means.