Patent Description:
In the sector capsules are known for the packaging of concentrated products (e.g., in the form of powder, granules, leaves) in predetermined, single-use doses, for the impromptu preparation of beverages (such as tea, coffee, herbal teas, milk, chocolate, etc.) by means of the introduction, into said capsule, of a fluid under pressure (mostly hot water). The penetration of the essence to be infused or dissolved contained inside the capsule by said flow of hot water, delivered by an extraction machine, results in the impromptu preparation of the beverage.

Different types of automatic or semi-automatic beverage preparation machines are known in the industry.

A first type of machine envisages the perforation of the capsule on both sides, in order to allow the pressurized fluid to be injected into the cup on one side, and the beverage to flow out from the opposite side. This first type of machine is intended for very simple capsules, comprising a cup closed on both sides, respectively by a bottom and a cover.

A second type of machine envisages perforating the capsule only on one side to allow pressurized fluid to be injected into the cup. This second type of machine is in fact intended for complex capsules, comprising a cup equipped with an outlet for the beverage on one side and a closing cover on the opposite side, as well as its own inner opening means. Said opening means, usually in the form of cutting or piercing tips or contours, are activated by increasing the pressure within the cup to pierce or tear an inner sealing disc and thereby allow the beverage to escape from the outlet opening at the bottom of the cup. This type of capsule is rather complex from the construction point of view, especially with regard to the construction of the opening means.

Typically, to make and dispense the beverage, the flow of hot water is injected inside the capsule with a pressure of about <NUM> atmospheres for a time ranging from <NUM> to <NUM> seconds. Thus, the capsules on the market are mainly made of mineral and synthetic materials such as, for example, aluminum and plastic, which provide said capsule with the necessary features to resist mechanical stresses, in particular pressure, and thermal stresses to which it is subjected during use.

As it is well known, these capsules are single-use and once the dispensing of the beverage is over, they become waste which is difficult to dispose of because of the materials from which they are made. In a more environmentally responsible vein, capsules have been made of biodegradable and/or compostable materials, as described for example in <CIT> aimed at a compostable coffee capsule. As explained in <CIT>, the features that a material must possess in order to be defined as "compostable" are set forth in European Standard EN <NUM> "Requirements for packaging recoverable through composting and biodegradation - Test scheme and evaluation criteria for the final acceptance of packaging. " <CIT> describes a capsule comprising a very simple cup, enclosed by a bottom and a cover, and intended for machines that envisage the simultaneous perforation of the capsule on both sides. Document <CIT> discloses a compostable capsule that forms the basis for the preamble of claim <NUM>.

In the sector, biodegradable and/or compostable capsules are known only of the type comprising a cup closed on both sides and intended for machines that envisage the simultaneous perforation of the capsule on both sides.

However, in order to create proper water pressure inside the cartridge and to ensure optimal extraction quality, the opening of the dispensing side of the capsule should only occur after the injection of the pressurized fluid.

In the sector, there is therefore a need for a biodegradable and/or compostable capsule provided with its own inner opening means that are activated only after the injection of the pressurized fluid. As mentioned above, however, this type of capsule is rather complex from the construction point of view, especially with regard to the construction of the opening means. This complexity is accentuated when using biodegradable and/or compostable materials, which are typically characterized by poor mechanical and thermal features.

The object of this invention is to construct a capsule for the preparation of infusion or soluble beverages that solves the problems of the prior art while taking into account the needs of the industry.

In particular, it is an object of this invention to provide a biodegradable and/or compostable capsule that is self-opening by the increase of the internal pressure and that is capable of withstanding the mechanical and thermal stresses to which it is subjected during use.

This object is achieved by a capsule for preparing infusion or soluble beverages according to claim <NUM>. The dependent claims describe preferred embodiments of the invention.

The features and advantages of a capsule for the preparation of infusion or soluble beverages according to this invention will become apparent from the following description, given by way of non-limiting example and according to the accompanying figures, wherein:.

With reference to the attached figures, a capsule for the preparation of infusion or soluble beverages is shown, indicated by the reference number <NUM>.

The capsule <NUM> comprises a body or cup <NUM> suitable to define an inner volume V wherein at least one substance S to be infused or dissolved, typically in powder or granular form, is contained.

On one side, the cup <NUM> is provided with a bottom <NUM> and on the opposite side with an inlet opening <NUM> defined by an externally projecting edge <NUM>.

The capsule <NUM> comprises a cover <NUM> fastened to the edge <NUM> to seal the cup <NUM> on top.

The capsule <NUM> comprises a sealing disc <NUM>, arranged within the cup <NUM>, which closes the capsule <NUM>. In effect, between the cover <NUM> and the disc <NUM> the inner volume V is defined wherein the substance S to be infused or dissolved is contained.

At the bottom <NUM>, the cup <NUM> is provided with an outlet opening <NUM> to allow the outflow of the infused beverage.

In the example of <FIG>, a plurality of inner windows <NUM> flow into a nozzle <NUM> terminating in the outlet opening <NUM>. In use, the beverage flows into the nozzle <NUM> which directs it into the final container, such as a cup or a glass.

In the example in <FIG>, a plurality of inner windows <NUM> open into a compartment <NUM> terminating in the outlet opening <NUM>. In said example, the capsule <NUM> is in effect provided with a protuberance <NUM>, at the central portion <NUM> of the base <NUM>, facing the inside of the cup <NUM> in the direction of the cover <NUM>. The compartment <NUM> defines a space of a size suitable to accommodate a lower perforation element of the machine for preparing the beverage. In use, in the compartment <NUM>, without coming into contact with the capsule <NUM>, the perforation element of the machine is inserted, which then acts only as a dispensing element as it is provided with channels for collecting the beverage and conveying it into the final container, such as a cup or a glass.

The cup <NUM> comprises therein a base <NUM>, shown for example in <FIG> and <FIG>, provided with a plurality of vertically projecting protuberances. The surface of the protuberances is substantially flat and free of cutting, piercing, or tearing elements. In effect, the sealing disc <NUM> that closes the capsule <NUM> is fastened by means of gluing or welding on the surface of the protuberances of the base <NUM>. The disc <NUM> is in effect located between the inner volume V and the base <NUM>, below the substance <NUM>.

The cup <NUM> is made of biodegradable and compostable material.

Preferably, the cup <NUM> is made of compostable material suitable for ensuring dimensional stability and thermal and mechanical resistance. An example of suitable materials for this object are compostable polyesters, particularly polylactic acid (PLA) and polybutylene succinate (PBS) and/or polyhydroxyalkanoate (PHA).

In one example, talc is added to the layer of material comprising polylactic acid (PLA) and/or polybutylene succinate (PBS) and/or polyhydroxyalkanoate (PHA). The talc content in this layer of material is between <NUM>% and <NUM>%, preferably between <NUM>% and <NUM>%.

Preferably, the cup <NUM> is made of a compostable material comprising polylactic acid (PLA) and/or polybutylene succinate (PBS).

Preferably, the cup <NUM> is made of a compostable material comprising polylactic acid (PLA) and/or polybutylene succinate (PBS) having at least one of the following features:.

In an example embodiment, the cup <NUM> is made of a compostable material comprising polylactic acid (PLA) and having at least two of the following features:.

In an example embodiment, the cup <NUM> is made of a compostable material comprising polybutylene succinate (PBS) and having at least two of the following features:.

In an example embodiment, the cup <NUM> is made of a compostable material comprising polyhydroxyalkanoate (PHA) and having at least two of the following features:.

Said features make it possible to obtain a compostable cup <NUM> with high thermal and mechanical resistance that may be penetrated by a flow of liquid at high temperature (between <NUM>° and <NUM>) and pressure (between <NUM> and <NUM> bar) for the entire dispensing time (about <NUM> minute) without softening and deforming (e.g. at the bottom and at the nozzle) and without breaking (e.g. at the side walls).

Preferably, the cup <NUM> has a wall thickness between <NUM> and <NUM>, preferably between <NUM> and <NUM>.

The cup <NUM> is made of compostable material, which is typically characterized by poor mechanical and thermal properties. Therefore, the bottom <NUM> of the cup <NUM> has been externally reinforced with outer reinforcement fins <NUM>. Said outer reinforcement fins are arranged at the labyrinth portion <NUM>. Preferably, the outer reinforcement fins <NUM> extend radially and form a uniform circumferential succession. Preferably, the outer reinforcement fins <NUM> are provided in large numbers to provide adequate support for the bottom <NUM> when the pressure inside the cup <NUM> increases. For example, the outer reinforcement fins <NUM> are provided in a number greater than <NUM>.

Moreover, in the variant embodiment of <FIG>, center reinforcements <NUM> have also been added at the center portion <NUM>. Preferably, the central reinforcements <NUM> extend radially and form a uniform circumferential succession. Preferably, the central reinforcements <NUM>, which are substantially triangular in shape, are provided in a number greater than <NUM>.

The cover <NUM> is also made of biodegradable and compostable material.

Preferably, the cover <NUM> is a multilayer compostable material having at least one layer that acts as an oxygen and/or vapor barrier. For example, said barrier layer is the top outer layer, made of metallized cellulose.

Preferably, the cover <NUM> has at least one layer made of compostable material comprising polylactic acid (PLA) and/or polybutylene succinate (PBS) and/or polyhydroxyalkanoate (PHA). For example, said layer is the lower outer layer in order to provide a compostable material compatible with the welding to the cup <NUM>.

Preferably, the cover <NUM> is made of a multilayer compostable material having at least one of the following features:.

The disc <NUM> is made of biodegradable and compostable material.

In the variant in <FIG>, the disc <NUM> is fully flexible.

In the variants in <FIG>, the disc <NUM> is only partially flexible. The material described below refers to the flexible part.

Preferably, the disc <NUM> is a multilayer compostable material having at least one layer that acts as an oxygen and/or vapor barrier. For example, said barrier layer is an intermediate layer made of metallized cellulose or metallized cellophane.

Preferably, the disc <NUM> has at least one layer made of a compostable material suitable to be in contact with the food substance contained in the cup <NUM>. For example, such a layer is the top outer layer, made of paper or cellophane.

Preferably, the disc <NUM> has at least one compostable material layer comprising polylactic acid (PLA) and/or polybutylene succinate (PBS). For example, said layer is the lower outer layer in order to provide a compostable material compatible with welding to the cup <NUM>.

Preferably, the disc <NUM> is a multilayer compostable material having at least one of the following features:.

Said features make it possible to obtain a compostable disc <NUM> with high thermal and mechanical resistance that may withstand the action of a flow of liquid at high temperature (between <NUM>° and <NUM>) and pressure (between <NUM> and <NUM> bar) for the entire dispensing time (about <NUM> minute) without softening and deforming completely to such an extent that it does not allow the capsule to open correctly or even it adheres completely to the base <NUM> of the cup <NUM>, closing the discharge passageway of the beverage.

In the variant of <FIG>, the disc <NUM> also comprises a rigid portion. In this variant, the rigid part is made of the same material used for the cup <NUM>.

As shown in <FIG> and <FIG>, the base <NUM> comprises a central portion <NUM> covering the at least one outlet opening <NUM>. The base <NUM> further comprises at least one substantially annular-shaped labyrinth portion <NUM> arranged concentrically about the central portion <NUM>, and consequently about the outlet opening <NUM>. The base <NUM> also comprises a perimeter edge <NUM> to which the sealing disc <NUM> is attached by gluing or welding.

The base <NUM> is provided, between the perimeter edge <NUM> and the labyrinth portion <NUM>, with a collection depression <NUM> suitable to collect the infused beverage and allowing it to flow toward the labyrinth portion <NUM>. The collection depression <NUM> defines a space suitable to accommodate, without obstructing it, the deformation of the sealing disc <NUM>, or at least a portion thereof, when the pressure exerted by the fluid within the capsule <NUM> reaches a certain opening threshold level.

The base <NUM> is further provided, between the labyrinth portion <NUM> and the central portion <NUM>, with a conveying depression <NUM> suitable to collect the infused beverage and allow it to flow, through the at least one outlet opening <NUM>, to the outside of the capsule <NUM>.

The labyrinth portion <NUM> has a plurality of capillary channels <NUM> that allow the beverage to flow toward the outlet opening <NUM> and then out of the capsule <NUM>. Conversely, said capillary channels <NUM> prevent the passage of the beverage when the pressure inside the capsule <NUM> drops below a threshold value, to prevent the beverage from dripping at the end of dispensing.

Each capillary channel <NUM> connects the collection depression <NUM> with the conveying depression <NUM>.

The capillary channel <NUM> is closed at the top by the disc <NUM> made of compostable material, which typically has poor mechanical and thermal properties. When the disc <NUM> is a flexible film made of compostable material, as the pressure and temperature in the capsule <NUM> increases, it tends to soften and adhere to the contour of the base <NUM>.

Thus, the capillary channels <NUM> have been made with a smaller cross section, to avoid possible obstructions by the sealing disc, and with an elevated length, to ensure an effective anti-drip effect.

Preferably, the capillary channel <NUM> has a zigzag or "square wave" pattern.

Preferably, the labyrinth <NUM> comprises a number of capillary channels <NUM> between <NUM> and <NUM>, preferably between <NUM> and <NUM>.

The labyrinth portion <NUM> comprises capillary channels <NUM> separated by dividers <NUM> on which the sealing disc <NUM> is permanently attached. Preferably, the surface occupied by the dividers <NUM> is greater than the surface occupied by the capillary channels <NUM> to adequately support the sealing disc <NUM> made of compostable material.

As mentioned above, when the disc <NUM> is a flexible film of compostable material, as the pressure and temperature in the capsule <NUM> increases, it tends to soften and adhere to the contour of the base <NUM>.

Therefore, the capsule <NUM> is provided, at the base <NUM>, with supports <NUM> suitable to keep the sealing disc <NUM> raised during the self-opening phase so that it does not adhere completely to the bottom of the collection depression <NUM>, thus preventing the discharge of the beverage. Preferably, the supports <NUM> are radial protrusions arranged at the bottom of the collection depression <NUM>.

Preferably, the capsule <NUM> is provided, at the base <NUM>, with supports <NUM> on which the sealing disc <NUM> is fastened or at least supported during the pre-opening phase. Preferably, the supports <NUM> are circular arc protuberances projecting from the bottom of the collection depression <NUM>. When provided, the supports <NUM> define a plurality of recesses <NUM> or compartments therebetween. In particular, a recess <NUM> is defined between a pair of adjacent supports <NUM>. The recess <NUM> defines a space suitable to accommodate, without obstructing it, the deformation of at least a portion of the sealing disc <NUM> when the pressure exerted by the fluid within the capsule <NUM> reaches a certain opening threshold level. The recess <NUM> defines a preferred space for the deformation of the disc <NUM>.

Preferably, when the substance S is ground coffee, the capsule <NUM> comprises a filter <NUM> fastened below the substance <NUM>, just above the disc <NUM>.

The filter <NUM> is made of biodegradable and compostable material.

Preferably, the filter <NUM> is made of paper fiber or cellulose and comprises polylactic acid (PLA) and/or polybutylene succinate (PBS) at least on the lower side to provide a compostable material compatible with the welding to the cup <NUM>.

Preferably, when the substance S is ground coffee, the capsule <NUM> comprises a film <NUM>, permeable or microperforated, fastened at some distance above the substance S, below the cover <NUM>. The film <NUM> is equipped with holes to allow the uniform passage of the injected fluid from the machine toward the food powder.

The film <NUM> is made of biodegradable and compostable material.

Preferably, the film <NUM> is made of polylactic acid (PLA) and/or polybutylene succinate (PBS) at least on the lower side to provide a compostable material compatible with welding to the cup <NUM>.

As shown in <FIG> and <FIG>, the capsule <NUM> for the preparation of infusion or soluble beverages comprises a sealing disc <NUM> adapted to seal the cup <NUM> on the bottom.

The disc <NUM> is fastened to the base <NUM> in an at least partially releasable manner such that it at least partially detaches therefrom by the increase in pressure within the volume V in which the food substance S is contained.

The disc <NUM> is fastened, either permanently or releasably, to the perimeter edge <NUM>.

The disc <NUM> is permanently fastened to the labyrinth portion <NUM> and the central portion <NUM>.

In use, the capsule <NUM> is inserted into a slot provided in the extraction machine, which pierces the cover <NUM> and introduces a pressurized fluid (mostly hot water) into the inner volume V in which the substance S is contained. The presence of the sealing disc <NUM> closing the bottom <NUM> of the capsule <NUM> allows the pressurized fluid to remain for a certain time interval in contact with the substance <NUM> to be infused or dissolved, ensuring an optimal beverage. The pressure exerted by the fluid inside the capsule <NUM> rises until it reaches a certain threshold level, or opening pressure (e.g., between <NUM> and <NUM> bars), which pushes on the disc <NUM> until it causes the self-opening that allows for the outflow of the beverage.

In particular, as shown in <FIG>, the opening of the capsule <NUM> is caused by the at least partial deformation of the sealing disc <NUM>.

In the variant embodiment shown in <FIG>, the capsule <NUM> opens according to a first self-opening mode. In such a variant embodiment, the sealing disc <NUM> is flexible, made in one piece, free of weak spots or cuts, and attached in an at least partially releasable manner to the perimeter edge <NUM>. Due to the increase in pressure within the capsule <NUM>, an outer edge of the disc <NUM> deforms and separates at least partially from the perimeter edge <NUM> causing the previously provided sealing effect to fail and a passageway P to open for the outflow of the beverage.

In the embodiment shown in <FIG>, the capsule <NUM> opens according to a second self-opening mode. In said variant embodiment, the sealing disc <NUM> is a composite disc, that is, comprising a central portion <NUM> and an outer annular portion <NUM> fastened to each other in an at least partially releasable manner.

The disc <NUM> is permanently fastened to the base <NUM>, i.e., at least to the perimeter edge <NUM> and to the labyrinth portion <NUM>. As seen in <FIG> and <FIG>, the outer edge <NUM> of the annular portion <NUM> is fastened on the perimeter edge <NUM> of the base <NUM>, and the center of the central portion <NUM> is fastened to the labyrinth portion <NUM>. The inner edge <NUM> of the annular portion <NUM> is fastened in an at least partially releasable manner to the perimeter edge <NUM> of the central portion <NUM>.

As discussed above, when the disc <NUM> is a flexible film made of compostable material, as the pressure and temperature in the capsule <NUM> increases, it tends to soften and adhere to the contour of the base <NUM>. Thus, in the capsule <NUM>, the disc <NUM> comprises a rigid portion and a flexible portion joined together. This reduces the risk of the disc <NUM> softening and adhering completely to the base.

Preferably, the edge of the flexible portion is fastened below the edge of the rigid portion. As a result of the increase in pressure within the capsule <NUM>, the flexible portion of the disc <NUM> deforms and separates at least partially from the rigid portion causing the previously provided sealing effect to fail and opening at least one passageway P for the outflow of the beverage.

In the example in <FIG>, in the capsule <NUM>, the central portion <NUM> of the disc <NUM>, intended to cover at least the labyrinth portion <NUM>, is a rigid disc. This reduces the risk of the disc <NUM> softening and obstructing the capillary passages <NUM>. The annular portion <NUM> is on the other hand a flexible film so as to be able to deform at least partially and allow the capsule <NUM> to open.

In the example of <FIG>, in the capsule <NUM>, the annular portion <NUM> of the disc <NUM>, intended to be fastened to the perimeter edge <NUM>, is rigid. This makes it easier for it to be welded to the perimeter edge <NUM>.

In the variant embodiment of <FIG> and <FIG>, the central portion <NUM> and the annular portion <NUM> are fastened to each other by means of a releasable circular weld. Therefore, due to the increase in pressure within the capsule <NUM>, the flexible portion of the disc <NUM> deforms and separates completely from the rigid portion forming one wide passageway P for the outflow of the beverage.

In the variant embodiment of <FIG> and <FIG>, the central portion <NUM> and the annular portion <NUM> are fastened to each other by a partially releasable circular weld. Therefore, due to the increase in pressure within the capsule <NUM>, the flexible portion of the disc <NUM> deforms and only partially separates from the rigid portion forming a plurality of small passageways P for the outflow of the beverage.

A capsule according to this invention is usable for packaging concentrated products (in the form of powder or granules or leaves) in predetermined, single-use doses, for the impromptu preparation of beverages such as leaf or soluble tea, ground or instant coffee, herbal teas, milk, chocolate, or other dehydrated and soluble products.

Innovatively, a capsule for the preparation of infusion or soluble beverages according to this invention is fully biodegradable and compostable and provided with its own inner opening means which are activated only later with respect to the injection of the pressurized fluid.

Advantageously, the biodegradable and compostable capsule according to this invention is self-opening by increasing the internal pressure and is able to withstand the mechanical and thermal stresses to which it is subjected during use.

Advantageously, the biodegradable and compostable capsule according to this invention is provided with reinforcements on the bottom to resist the mechanical and thermal stresses to which it is subjected during use.

Advantageously, the biodegradable and compostable capsule according to this invention is self-opening by the at least partial deformation of a partially rigid sealing disc to resist the mechanical and thermal stresses to which it is subjected during use.

Claim 1:
A compostable capsule (<NUM>) for making infusion or soluble beverages, comprising:
- a cup (<NUM>) in which there is defined an inner volume (V) in which there is contained at least one substance (S) to be infused or dissolved; said cup (<NUM>) being provided:
-- on one side, with a bottom (<NUM>) with an outlet opening (<NUM>) for the beverage,
-- on the opposite side, with an inlet opening (<NUM>) of a fluid;
-- internally with an inner base (<NUM>) comprising:
--- a central portion (<NUM>) covering the opening (<NUM>),
--- a labyrinth portion (<NUM>) arranged about the central portion (<NUM>),
--- a perimeter edge (<NUM>) arranged about the central portion (<NUM>),
--- a beverage collection depression (<NUM>) arranged between the perimeter edge (<NUM>) and the labyrinth portion (<NUM>),
--- a beverage conveying depression (<NUM>) arranged between the labyrinth portion (<NUM>) and the central portion (<NUM>);
- a cover (<NUM>) sealingly fastened to the cup (<NUM>), to close the opening (<NUM>);
- an at least partially flexible sealing disc (<NUM>) sealingly fastened on the inner base (<NUM>) of the cup (<NUM>) to ensure, together with the cover (<NUM>), a seal of the inner volume (V);
wherein the opening for the outflow of the beverage is determined by the at least partial deformation of the sealing disc (<NUM>), a deformation which loses the sealing of the volume (V);
wherein the cup (<NUM>), the cover (<NUM>), and the sealing disc (<NUM>) are made of compostable material;
characterized in
that the cup (<NUM>), the sealing disc (<NUM>) and the cover comprise polylactic acid (PLA) and/or polybutylene succinate (PBS) and/or polyhydroxyalkanoate (PHA).