Patent Description:
Single-serve containers have become a very popular method of preparing coffee and other infusions. They generally contain enough coffee for a single portion, and are used in conjunction with a suitable machine which uses the containers to brew the infusion. Single-serve coffee containers can both reduce the time needed to brew coffee and simplify the brewing process by eliminating the need to measure out portions, flavourings, and additives from large bulk containers. They can also help to keep the unused product fresher by individually packaging portions separately without exposing the entire supply batch to air and light.

For coffee, the containers currently come in a number of forms. Coffee pods are pre-packaged ground coffee beans in their own filter. Coffee bags are modelled on tea bags, and consist of a gauze bag containing a mixture of instant coffee and finely ground roast coffee, which is to be steeped in hot water for approximately three minutes. Coffee capsules comprise a plastic or aluminium package (instead of a paper filter) which contains the coffee, are usually designed for use with a single brand or system, and are often not interchangeable with other systems. An example of a coffee capsule is shown at <CIT>.

Paper coffee pods, such as those used in 'Easy Serving Espresso Pod' ('ESE Pod') or Senseo™ machines have the benefit of being a fully biodegradable product that can decompose naturally. The plastic and/or metal capsules such as those used in the Keurig®, Tassimo® and Nespresso® machines are generally not recyclable as they are often composed of a mix of plastic, aluminium, and organic material (the used coffee) which makes them difficult to recycle. As a result, in <NUM> the German city of Hamburg banned coffee capsules from state-run buildings on environmental grounds.

The capsules generally have defined standard dimensions, which enables them to fit into a range of compatible machines and work reliably. Where compatible capsules are available from multiple sources, the various manufacturers generally aim to conform closely to the standard dimensions of the capsule system in question, so that their capsules will fit and will work reliably.

The company Nowpresso Limited of Kowloon, Hongkong has proposed a recycling device which allows separation of some elements of certain capsules. As shown at https://nowpresso. com/, it consists of a base with an aperture sized to allow a standard aluminium Nespresso™ capsule to sit over the aperture, supported by its rim on a flat annular surface surrounding the aperture. A plunger is provided to compress the capsule against the annular surface, which collapses and inverts the aluminium capsule, expelling the used coffee grounds into a receptacle below and thus leaving just the aluminium behind. The two elements of the capsule can then be recycled separately.

<CIT> and <CIT> disclose a tool which accommodates a coffee capsule, and which can be safely placed over a collecting cup for collecting the coffee grounds. The capsule is placed over a central aperture and crushed to expel the grounds.

<CIT> discloses a mechanically-driven plunger for crushing and inverting an infusion capsule.

The present invention seeks to improve upon the Nowpresso device, which generally only works with silicone-sealed capsules, and is less able to cope with other designs of capsule - especially those which employ seal arrangements that are intrinsically more recycleable.

The present invention therefore provides a device for separating infusion capsules, comprising a base unit and a plunger, the base unit having a face with an aperture for receiving a body part of the capsule, wherein a portion of the face surrounding the aperture has a surface that undulates in a longitudinal direction relative to a central axis through the aperture; the plunger comprising a projection sized to fit within the aperture.

A capsule can be placed, rim side down, on the base unit over the aperture, and the plunger used to urge the capsule down into the aperture. The result is that the capsule inverts, rupturing the foil layer and emptying the coffee or other infusion into the base unit below the aperture. The coffee (etc) and the capsule can then be removed for separate recycling. The undulating surface ensures that the rim section of the capsule is distorted during this process, which assists in separating any layers that have been provided for example by way of sealant. Some capsules crimp the rim and seal with a silicone or similar composition; other more recyclable capsules employ a paper seal which is separated by the device of the present invention thus allowing each element to be recycled appropriately.

We prefer that the portion is level in the radial direction relative to the central axis, as this assists in retaining the capsule in place during the process. The undulations are thus in the longitudinal direction, and preferably includes at least one section that is helical relative to the central axis. Other sections that are preferable to include are substantially upright relative to the face. Overall, we particularly prefer that the surface includes at least one part consisting of, in order, a sub-section that is substantially upright relative to the face; a sub-section that is helical relative to the central axis in a first direction, a sub-section that is helical relative to the central axis in a second direction, opposed to the first direction, and a sub-section that is substantially upright relative to the face. Ideally, the surface comprises two such parts; these can be separated by two flat sections, and are preferably arranged rotationally symmetrically around the central axis.

The face can one or more upstanding ridges surrounding the portion. These act to locate the capsule correctly over the aperture, and prevent it from spreading outwardly during the process. Thus, the ridges are ideally located so as to surround a rim of a standard-sized infusion capsule.

Most capsules are circularly symmetric, so we prefer that the aperture is circular. It should be sized to receive a body of a standard-sized infusion capsule, but not an exterior rim thereof.

We prefer that the projection (of the plunger) is sized so that, when fully inserted via the aperture, it extends beyond the face by a distance which is not greater than but is a substantial part of the depth of a standard-sized infusion capsule. The result of this is that the plunger substantially completely inverts the capsule when pressed, ejecting as much of the content of the infusion capsule as possible instead of allowing some to be trapped in creases in the capsule material. This also means that the emptied capsules can be stacked, reducing the space needed for storage while they are awaiting recycling.

We also prefer that the projection has a tip for contacting the infusion capsules which is concave. This self-centres the top of the capsule centrally onto the plunger, meaning the capsules correctly align themselves and the inversion process is more consistent.

The infusion capsule will usually contain ground coffee, but the invention can be applied to capsules containing other infusions.

An embodiment of the present invention will now be described by way of example, with reference to the accompanying figures in which;.

<FIG> shows a base unit <NUM> according to the present invention, in section. A hollow cup-shaped receptacle <NUM> is generally cylindrical in form, with a closed lower face <NUM> and an open upper face <NUM>. A lid <NUM> is located over the open upper face <NUM>; the lid <NUM> is circular in order to match the cylindrical shape of the receptacle. It has a downwardly-depending skirt <NUM>; this is cylindrical and located concentrically on the lid <NUM>, sized to fit within the receptacle <NUM>. Alternatively, if the receptacle <NUM> is not cylindrical, the skirt <NUM> could be shaped correspondingly or otherwise appropriately in order to locate the lid <NUM> over the receptacle <NUM>. Alternatively, or in addition, the skirt <NUM> could locate around the exterior of the receptacle <NUM>. A set of lugs (not shown) on the outer face of the skirt <NUM> locate within dog-leg shaped keyways <NUM> on the interior face of the receptacle <NUM> to allow the lid <NUM> to be releasably fastened in place over the receptacle <NUM>. In this case there are two lugs, located symmetrically opposite each other, but this could be varied.

The lid <NUM> has an outer rim <NUM> which serves to contain any spilled material, and provides additional rigidity to the lid <NUM>. This extends upwardly from the outer edge of the lid <NUM> and is also cylindrical in form. It could be of a different shape, or it could be omitted.

The lid <NUM> also has a central aperture <NUM>, which can also be seen in <FIG>. This is circular, and located concentrically on the lid <NUM>; this positioning is not essential but does make operation of the device more straightforward. The aperture is surrounded by a pair of upstanding ridges <NUM>, <NUM> which (together) encircle about <NUM>% of the aperture <NUM> leaving a pair of radially-opposed gaps between them for the remainder. Generally, the ridges <NUM>, <NUM> should occupy at least about <NUM>% of the circumference around the aperture <NUM>.

<FIG> shows the complete device, in section, with a standard Nespresso®-compatible capsule <NUM> in place over the aperture <NUM>. These capsules <NUM> conform to a standard set of dimensions which are generally known and were established by the originators of the design; in order to be compatible, capsules <NUM> must adhere to these dimensions so that they fit correctly into compatible brewing machines and operate correctly and safely. Accordingly, it is possible to be confident that the dimensions of the capsule <NUM> will be predictable. Other infusion capsule systems exist, and if the skilled person wishes to design a device adapted to such a system then the appropriate changes can be made to the dimensions of the device.

From <FIG>, it is apparent that the capsule <NUM> has a tapering body portion <NUM> ending at its widest point with a flange <NUM> onto which is fixed a foil lid <NUM>, and at its narrowest point with a closed dome section. The body portion <NUM> is made of a thin aluminium sheet and the lid <NUM> of a fine aluminium foil which is sealed onto the flange. The sealing step can be carried out in a range of manners, such by an adhesive between the flange <NUM> and the lid <NUM>, or by wrapping the lid <NUM> around the flange <NUM> and applying an annular-shaped adhesive tape <NUM> over the flange <NUM> and the lid <NUM>.

<FIG> also shows that the aperture <NUM> is sized to accept the body portion <NUM> of the capsule <NUM>, but not the flange <NUM>. Thus, when the capsule <NUM> is placed body-portion-uppermost over the aperture <NUM>, it will rest on the edges of the aperture <NUM>, supported by flange <NUM>. The ridges <NUM>, <NUM> are located so that they are positioned immediately surrounding the flange <NUM>, thus allowing the capsule <NUM> to be placed accurately and held in position concentrically over the aperture <NUM>.

<FIG> also shows the plunger unit <NUM>. This consists of an inverted cylindrical cup section <NUM>, shaped and sized to fit over and around the receptacle <NUM>. It has an upper lid <NUM>; this supports a concentric ring <NUM> which serves as a stop to limit how far the plunger <NUM> can be pressed down onto the base unit <NUM>; eventually the ring <NUM> will meet the lid <NUM> and prevent further movement. In the centre of the plunger <NUM>, there is a projection <NUM> sized to fit within the aperture <NUM>, and also located centrally on the plunger <NUM> so that it will pass through the aperture <NUM>. The tip of the projection <NUM> has a concave recess <NUM> which is sized to fit over the dome section atop the capsule <NUM>. Thus, the plunger <NUM> can be positioned over the base unit <NUM> with a capsule <NUM> in place as described above, and the plunger depressed so as to urge the projection into contact with the capsule <NUM>. This will then lead to the state shown in <FIG>, with the projection <NUM> having caused the foil lid <NUM> to rupture, inverted the body portion <NUM>, and ejected the contents <NUM> of the capsule <NUM> into the receptacle <NUM>.

The working length of the projection <NUM>, i.e. the height H of the projection <NUM> over the ring <NUM> (or whatever part of the plunger <NUM> limits its movement downwards over the base unit <NUM>) is less than the overall height of the standard-sized capsule <NUM>, but only by a small margin. Thus, the working length H is a substantial part of the height of the capsule. This ensures that the capsule is fully inverted, ejecting as must of the contents <NUM> as is possible. The concave recess <NUM> and the ridges <NUM>, <NUM> each assist in ensuring that the capsule <NUM> remains in position during its inversion. Thus, the tapering nature of the capsule <NUM> means that the net force at the flange <NUM> is generally outwards, and therefore the flange is restrained effectively by the surrounding ridges <NUM>, <NUM>. At the top of the capsule <NUM>, the concave recess <NUM> retains the dome section of the capsule <NUM> and prevents it from moving sideways, thus keeping the capsule aligned correctly.

Between the aperture <NUM> and the ridges <NUM>, <NUM>, there is a supporting ledge <NUM> on which the flange <NUM> rests (above). The dotted lines <NUM> in <FIG> indicate the extent of the supporting ledge <NUM> in the gaps between the ridges <NUM>, <NUM>. According to the present invention, this supporting ledge <NUM> is not flat. We have found that by providing a non-flat supporting ledge <NUM>, the flange is disrupted or distorted during the inversion process which causes any adhesive tape <NUM> placed over the flange <NUM> as a seal to be separated from the flange <NUM>. After the inversion process is complete, as a result of the non-flat nature of the supporting ledge <NUM>, the adhesive tape <NUM> is usually detached from the remainder of the capsule. As a result, the capsule is effectively separated into its three material components; the contents <NUM> are in the receptacle <NUM>, the aluminium parts are sitting over the aperture <NUM>, and the adhesive tape is lying loosely over the aluminium parts. Separation of the materials for recycling is therefore straightforward.

The particular non-flat shape of the supporting ledge <NUM> shown in the embodiment of <FIG> comprises a bihelical slope on the inner side of each of the upstanding ridges <NUM>, <NUM>. This slope results in the ledge <NUM> being highest adjacent the ends of the ridges <NUM>, <NUM> (<FIG>) and lowest at the midpoint of the ridges <NUM>, <NUM> (<FIG>). Thus, at the ends of the ridges <NUM>, <NUM>, the ledge <NUM> is at approximately half the height of the ridges <NUM>, <NUM>. At the midpoint, the ledge <NUM> is level with the remainder of the outer face of the lid <NUM> on the other side of the ridges <NUM>, <NUM>. In the areas outside the ridges, i.e. in the gaps between the ridges <NUM>, <NUM>, the ledge <NUM> is flat and level with the remainder of the outer face of the lid <NUM>.

As a result, the non-flat shape of the ledge <NUM> consists, in this embodiment, of a sub-section <NUM> alongside a gap between the ridges <NUM>, <NUM> which is flat and level with the remainder of the outer face of the lid <NUM>, followed by (moving circumferentially around the aperture <NUM>) a substantially upright section <NUM> (relative to the surface of the lid <NUM>) which raises the level of the ledge <NUM> to about half the height of the ridge <NUM>) and then a sub-section <NUM> that descends helically (relative to a central axis through the aperture <NUM>) to a point midway along the ridge <NUM> at which point the ledge <NUM> is again level with the remainder of the outer face of the lid <NUM>. This is followed by a sub-section <NUM> that rises helically relative to the central axis, ending with a sub-section <NUM> that is substantially upright relative to the lid <NUM> at which the ledge drops to be level with the remainder of the outer face of the lid <NUM>. The ledge is then flat and level in the second gap between the ridges <NUM>, <NUM>, and the pattern is repeated adjacent the remaining ridge <NUM>.

Other non-flat profiles for the ledge <NUM> are of course possible. For example, a corrugated or sawtooth pattern could be provided. The pattern could be continuous around the aperture, or the intervals could be located elsewhere than in the gaps between the upstanding ridges <NUM>, <NUM>. Likewise, more gaps, fewer gaps, or no gaps could be provided in the upstanding ridges <NUM>, <NUM>. We have found that the profile described above and shown in <FIG> is straightforward to manufacture and effective in separating the elements of the capsule <NUM>, however.

Claim 1:
A device for separating infusion capsules (<NUM>), comprising a base unit (<NUM>) and a plunger (<NUM>),
the base unit (<NUM>) having a face with an aperture (<NUM>) for receiving a body part of the capsule (<NUM>);
the plunger (<NUM>) comprising a projection (<NUM>) sized to fit within the aperture (<NUM>);
characterised in that a portion of the face surrounding the aperture (<NUM>) has a surface (<NUM>) that undulates in a longitudinal direction relative to a central axis through the aperture (<NUM>).