WO2016037949A1

WO2016037949A1 - A machine-insertable beverage capsule and associated methods and systems

Info

Publication number: WO2016037949A1
Application number: PCT/EP2015/070301
Authority: WO
Inventors: Glen OLIVER
Original assignee: Koninklijke Douwe Egberts B.V.
Priority date: 2014-09-11
Filing date: 2015-09-04
Publication date: 2016-03-17
Also published as: GB201416074D0; GB2530062B; GB2530062A

Abstract

A machine-insertable beverage capsule (1) is provided comprising a cup-shaped body (2) and a lid (3). The cup-shaped body comprises a side wall (4), a base (5) at an inlet end of the cup-shaped body and a flange (6) at an outlet end of the cup-shaped body and has the lid sealed to the outlet end of the cup- shaped body. The capsule contains one or more extractable beverage ingredients and is suitable for insertion into a beverage preparation machine which is of the type having an enclosing member (10) and a perforation element (13) intended in use to pierce the base of the capsule. At least a portion of the base intended to be pierced in use is formed of a polymer and the base comprises a plurality of laser-formed features (60) to promote piercing, in use, of the base by the perforation element. The laser-formed features comprise one or more features selected from the group of: through apertures (61); and/or blind apertures (62). An associated system and methods are also disclosed.

Description

A Machine-lnsertable Beverage Capsule and Associated Methods and Systems

The present disclosure relates to machine-insertable beverage capsules and associated methods and systems. In particular, it relates to a machine- insertable beverage capsule for the preparation of a beverage, for example coffee, when utilised with a beverage preparation machine, the capsule comprising a body and a lid which together define an interior of the capsule for containing beverage ingredients. Further, the disclosure relates to methods for producing said capsules and components thereof and systems incorporating said capsules.

Background of the disclosure

Disposable beverage capsules formed from aluminium have been known for many years. An example is described in EP0512470. The capsule of that document comprises a frustroconically-shaped cup which is filled with coffee and is closed by an aluminium cover joined to a rim which extends from a side-wall of the cup. A capsule holder of a brewer designed to receive the capsules comprises a flow grill with relief surface element members. The brewer further comprises a water injector and an annular element with an internal recess of which the shape substantially corresponds to the outer shape of the capsule.

In operation, the capsule of EP0512470 is placed in the capsule holder. The water injector perforates an upper, inlet face of the capsule. The aluminium cover of the capsule rests on the relief surface element members of the capsule holder. Water is injected through the water injector and contacts the coffee. The capsule is pressurised by the water causing the aluminium cover to be distorted outwardly and be torn against the relief surface element members. Extracted coffee flows through the torn aluminium cover and the flow grill to be discharged by the brewer into a receptacle, for example a cup.

More recently, it has been known to manufacture beverage capsules of the general configuration described above, at least in part, from a polymeric material. For example, it is known to combine a cup-shaped body formed from a material such as a polyethylene (PE) or polypropylene (PP) polymer, with an aluminium- based cover to form the capsule. An example of such is described in

WO20107041 179. One potential problem is that beverage capsules made of a polymer such as PE or PP can be difficult to perforate using the inlet piercer of known beverage preparation machines which may already be on the market. For example, the material of the capsule may deflect or distort during the piercing stage resulting in the inlet aperture not being fully formed and the aperture therefore having a smaller open area than desired. In another example the force applied by the inlet piercer may be insufficient to fully form an inlet aperture of desired size in the material of the capsule, in particular where the material of the capsule is a relatively resilient polymeric material. In extreme cases, the capsule material may deflect or distort to such an extent, or the material of the capsule may be sufficiently resilient, that no aperture is formed at all.

Attempts have been made to overcome this problem by altering the geometry of the capsule to reinforce the capsule in the region where the inlet apertures are to be formed. WO2010/041 179 describes that the capsule may comprise a sunken portion provided in the inlet wall. This sunken portion is intended to be a reinforcing element that cooperates with a corresponding radial ridge on the inlet wall. WO2012/080501 describes a capsule where the base (that is the inlet wall) of the capsule is provided with a reinforcement zone arranged circumferentially on the base as a plurality of recesses. However, altering the geometry of the capsule requires a complete redesign of the capsule and can lead to the capsule becoming incompatible for use in some beverage preparation machines. In addition, increasing the reinforcement of the inlet wall can increase the problem of forming inlet apertures where the force applied by the inlet piercer is relatively low.

Summary of the Disclosure

In one aspect the present disclosure provides a machine-insertable beverage capsule comprising a cup-shaped body and a lid;

the cup-shaped body comprising a side wall, a base at an inlet end of the cup-shaped body and a flange at an outlet end of the cup-shaped body;

the lid being sealed to the outlet end of the cup-shaped body; the capsule containing one or more extractable beverage ingredients and being suitable for insertion into a beverage preparation machine to permit a pressurised liquid to be flowed through the capsule in order to produce a beverage from interaction with the extractable beverage ingredients;

the beverage preparation machine being of the type having an enclosing member and a perforation element adapted to be relatively movable between an open position to permit insertion of the capsule into the beverage preparation machine and a closed position in which the enclosing member sealingly engages the flange of the capsule and the perforation element pierces the base of the capsule;

wherein at least a portion of the base intended to be pierced in use is formed of a polymer;

wherein the base comprises a plurality of laser-formed features to promote piercing, in use, of the base by the perforation element, wherein the laser-formed features comprise one or more features selected from the group of:

- through apertures; and/or

- blind apertures.

Advantageously, by providing the base with the plurality of laser-formed features, the cup-shaped body can be configured as desired to allow it be pierced sufficiently and reliably in use by the beverage preparation machine. Whilst not wishing to be bound by theory the use of the plurality of laser-formed features allows for relatively large, elongate, openings to be formed in the base due to stretching and/or tearing and/or crack propagation of the polymeric material between adjacent laser-formed features. The presence of the through apertures and/or blind apertures allows for the path of the tearing and/or crack propagation to be predicted and controlled thereby allowing desired shapes of openings in the base to be obtained. Thus the plurality of laser-formed features help to promote piercing of the base by reducing the force required to perforate, stretch, tear or crack the base and/or by helping to control the shape of any elongate opening produced by providing predefined propagation paths for any cracks which preferentially form by extending between adjacent laser-formed features. Since the formation of the laser-formed features takes place after formation of the cup-shaped body (e.g. by moulding), the technique can be applied to cup-shaped bodies of any geometry and does not require a wholesale change in the shape of the capsule intended to be formed from the cup-shaped body. In addition, the laser-formed features may be formed on an outer or an inner face of the base or a mixture of the two.

Where the plurality of laser-formed features comprise only blind apertures then the capsule may be configured to be gas-tight. If desired the capsule may also comprise a material to act as a gas barrier. For example the capsule may be formed from a material comprising a polymeric material laminated to a layer of a barrier material such as EVOH. In this case, piercing of the capsule in use by the perforation element may involve forming openings by transforming one or more of the blind apertures in the base into through apertures by stretching and/or tearing and/or cracking of the polymer material at or near the blind apertures.

Alternatively, where the plurality of laser-formed features comprise at least some through apertures then an overwrap may be provided to seal the capsule within a gas-tight membrane prior to use. In this case, piercing of the capsule in use by the perforation element may involve, as above, forming openings by transforming one or more blind apertures (if present) in the base into through apertures by stretching and/or tearing and/or cracking of the polymer material at or near the blind apertures, but also may comprise forming openings by increasing the size of one or more of the pre-formed through apertures by stretching and/or tearing and/or cracking of the polymer.

In both cases, each opening so formed on piercing may encompass two or more of the pre-existing blind and/or through apertures.

Preferably, the plurality of laser-formed features are arranged in an annular zone of the base, said annular zone being centred on a central axis of the capsule and said annular zone at least encompassing that portion of the base intended to be contacted in use by the perforation element of the beverage preparation machine. Thus, the perforation element of the beverage preparation machine will be brought into contact with the base at the location of, or at least closely adjacent to, one or more of the plurality of laser-formed features. This helps to ensure consistent crack/perforation initiation.

Preferably, a remainder of the base outside said annular zone is free of laser-formed features. Advantageously, by confining the plurality of laser-formed features to only the annular zone, the effective open-area of the base (where the laser-formed features comprise at least some through apertures) can be kept to a minimum while maintaining the required perforation performance.

The plurality of laser-formed features may comprise at least one

circumferential array of features extending around a central axis of the capsule. It may be advantageous for the plurality of laser-formed features to define a pattern that is rotationally symmetric about the central axis of the capsule. In such a case the perforation performance of the capsule will be the same whatever the relative alignment of the capsule within the enclosing member in use.

The plurality of laser-formed features may comprise a plurality of transverse arrays of features extending from the circumferential array. The use of transverse arrays of features, in particular optionally in combination with circumferential arrays of features, is that crack propagation in two dimensions is encouraged. For example, the use of transverse arrays of features and

circumferential arrays of features can allow for a first crack to propagate circumferentially from a contact point of the perforation element with the base and a second crack to propagate transversely (i.e. at an orientation having at least a component in the radial direction). This can allow for the formation of larger openings that more consistently extend away from the perforation element. This allows for better water ingress into the capsule since the perforation element does not fully block the opening that has been formed. In addition the formation of crack propagation in two dimensions allows for the formation of flap portions and hinged portions in the base which may have the potential for creating significantly easier water ingress to the capsule since the travel of the perforation element as well as creating the cracks also may tend to deflect the flap portion or hinged portion inwardly into the cup-shaped body.

The plurality of laser-formed features may comprise two or more circumferential arrays of laser-formed features. As well as this, the features may comprise a plurality of transverse arrays of laser-formed features extending between the two or more circumferential arrays of laser-formed features. This type of pattern has been found to be beneficial in the formation of flap portions and hinged portions.

The plurality of laser-formed features may form a reticulated pattern extending circumferentially around a central axis of the capsule. In one example, the reticulated pattern comprises triangular forms. Again, the use of reticulated patterns has been found to be beneficial in the formation of flap portions and hinged portions.

The plurality of laser-formed features may define a pattern comprising vertexes formed as through apertures and links formed as blind apertures.

Advantageously, the use of through apertures at the vertexes of the pattern and blind apertures for the links may help to define more predictable cracking of the base. For example, cracks will tend to propagate along the links in preference to extending into the other parts of the base where the material is not thinned. Once a crack propagates to a blind aperture at a vertex the crack will either stop propagating or may continue to propagate along a subsequent link extending from said vertex. Therefore the use of blind apertures and through apertures can be used to control the extent and direction of crack propagation. In this way the crack direction may be controlled and directed to change direction. This may be beneficial in the formation of flap portions and hinged portions.

The plurality of laser-formed features may be sized and spaced relative to each other to promote formation of one or more elongated openings in the base on closure of the enclosing member by means of crack propagation between adjacent laser-formed features.

The one or more elongated openings may define a flap portion of the base which may be deflected inwardly into an interior of the capsule on closure of the enclosing member. As noted above, such flap portions or hinged portions can be beneficial in allowing easier water ingress into the capsule.

The through apertures may each have a maximum critical dimension of

500 microns, preferably a maximum critical dimension of 300 microns, more preferably a maximum critical dimension of 100 microns. By use of a laser to form the features in the polymer material through apertures with a critical dimension down to 3 microns can be produced. In the case where the through apertures comprise a plurality of round through holes, the maximum critical dimension is the diameter of said round through holes. In the case where the through apertures comprise a plurality of elongate holes, each elongate hole having a length greater than its width, the maximum critical dimension is the width of said elongate holes.

The blind apertures may each have a maximum critical dimension of 500 microns, preferably a maximum critical dimension of 300 microns, more preferably a maximum critical dimension of 00 microns. By use of a laser to form the features in the polymer material blind apertures with a critical dimension down to 3 microns can be produced. In the case where the blind apertures comprise a plurality of round blind holes, the maximum critical dimension is the diameter of said round blind holes. In the case where the blind apertures comprise a plurality of elongate blind holes, each elongate blind hole having a length greater than its width, the maximum critical dimension is the width of said elongate blind holes.

An advantage of using a laser to form the through/blind apertures is that accurate control of the critical dimension of the apertures is promoted. It has been found to be very difficult when trying to form apertures in a moulding process (e.g. by use of mould pins) or by punching holes in a pre-formed base to control consistently the critical dimension of each aperture. Where the aperture is too large the extractable beverage ingredient may be spilt out during transport. By contrast, since the formation of the laser-formed features may be carried out after moulding the cup-shaped body material will be more stable and variations in the apertures due to cooling and shrinking effects of the moulding process can be avoided. In addition, the use of a laser allows the formation of patterns of blind and/or through apertures which are much more intricate than are possible with other techniques.

The plurality of laser-formed features may comprise greater than 50, preferably greater than 100 individual through apertures and/or blind apertures.

A maximum distance between adjacent through apertures and/or blind apertures of the plurality of laser-formed features may be 3000 microns, preferably 1000 microns, more preferably 500 microns, more preferably 100 microns. Adjusting the maximum distance of separation between the laser- formed features may help to control the cracking performance of the base.

The plurality of laser-formed features may comprise a plurality of through apertures and a plurality of blind apertures.

The plurality of laser-formed features may comprise one or more arrays comprising through apertures interlinked by blind apertures.

In one example the plurality of laser-formed features comprises one or more arrays comprising round apertures (through and/or blind) interlinked by elongate apertures (through and/or blind).

The base may have a thickness in the range of 0.20 to 0.50mm, preferably within the range 0.30 to 0.40mm.

At least the portion of the base designed to be pierced in use may be formed of a material comprising a polyolefin, preferably a thermoplastic polyolefin, for example polypropylene and/or polyethylene. Alternatively, other polymers may be used, for example polylactic acid (PLA).

The polymer used for the base may comprise an additive intended to facilitate the formation of the plurality of laser-formed features by the radiant energy of the laser. The additive may be one or more compounds selected from the group of: carbon black, graphite and doped-tin dioxide. The tin dioxide may be doped with one or more of antimony, fluorine, chlorine, tungsten,

molybdenum, iron or phosphorus.

The cup-shaped body may be a unitary moulding, preferably an injection- moulding.

The flange of the cup-shaped body may further comprise a sealing member configured to form a sealing engagement with an enclosing member of a beverage preparation machine to thereby prevent or limit a by-pass flow of water in use.

In another aspect the present disclosure provides a cup-shaped body for forming a capsule as described above.

In another aspect the present disclosure provides a beverage producing system comprising:

a machine-insertable beverage capsule as described above; and a beverage preparation machine;

the beverage preparation machine having an enclosing member and a perforation element adapted to be selectively configurable between an open position to permit insertion of the capsule into the beverage preparation machine and a closed position in which the enclosing member sealingly engages the capsule and the perforation element pierces a base of the capsule.

In another aspect the present disclosure provides a method of preparing a beverage comprising the steps of:

- providing a machine-insertable beverage capsule as described above; - providing a beverage preparation machine having an enclosing member and a perforation element;

- positioning the enclosing member in an open position;

- inserting the capsule into the beverage preparation machine;

- closing the enclosing member so as to sealingly engage the enclosing member with the capsule;

- wherein during closure of the enclosing member the perforation element interacts with the base of the capsule to form one or more elongated openings in the base by means of crack propagation between adjacent laser-formed features of the capsule;

- flowing a pressurised liquid into the one or more elongated openings and through the capsule to produce a beverage from interaction with the beverage ingredients; and

- outputting the beverage for consumption.

Optionally, the one or more elongated openings define a flap portion of the base which is deflected inwardly into an interior of the capsule on closure of the enclosing member.

In another aspect the present disclosure provides a method of producing a cup-shaped body of a machine-insertable beverage capsule, the cup-shaped body comprising a side wall, a base at an inlet end of the cup-shaped body and a flange at an outlet end of the cup-shaped body;

the method comprising the steps of:

first forming the cup-shaped body from a polymeric material; subsequently, post-moulding, forming with a laser a plurality of through apertures and/or blind apertures in the base.

Forming the plurality of laser-formed features is carried out by use of a laser to expose portions of the base to radiant energy. Advantageously, the use of such radiant energy from a laser provides a very accurate means for selectively forming features in the base. In particular the location of the blind and/or though apertures can be accurately controlled and, as noted above, the size of individual features can be made much smaller than would be possible with alternative techniques - such as the use of pins within the mould tools which in the prior art have been used to form apertures at the same time as moulding the cup-shaped body.

The plurality of laser-formed features may be formed in an annular zone of the base, said annular zone being centred on a central axis of the capsule and said annular zone at least encompassing that portion of the base intended to be pierced in use by the perforation element of the beverage preparation machine.

A remainder of the base outside said annular zone may be left free of laser-formed features.

The plurality of laser-formed features may be formed to have at least one circumferential array of features extending around a central axis of the capsule.

The plurality of laser-formed features may be formed to have a plurality of transverse arrays of features extending from the circumferential array.

The method may comprise forming with the laser greater than 50, preferably greater than 100 individual through apertures and/or blind apertures in the base of the cup-shaped body.

A maximum distance between adjacent through apertures and/or blind apertures may be 3000 microns, preferably 1000 microns, more preferably 500 microns, more preferably 100 microns.

The method may comprise forming with the laser a plurality of through apertures and a plurality of blind apertures.

Brief Description of the Drawings Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 is a schematic view of a machine-insertable beverage capsule according to the present disclosure;

Figure 2 is a schematic view of the capsule of Figure 1 inserted into a beverage preparation machine and prior to piercing;

Figure 3 is an equivalent view to Figure 2 after piercing of an inlet end of the capsule;

Figure 4 is a schematic end view of the capsule of Figure 1 ;

Figure 5 is a schematic representation of an apparatus for treating a cup- shaped body of the capsule of Figure 1 ;

Figure 6 shows a perspective view of one example of machine-insertable beverage capsule according to the present disclosure;

Figures 7 and 8 show examples of possible alternative arrangements of laser-formed features in a base of the machine-insertable beverage capsule;

Figure 7a is an enlarged view of a portion of Figure 7;

Figures 9a and 9b are schematic representations showing the formation of laser-formed features in a polymer; and

Figure 10 is a graph comparing the force to pierce two capsules.

Detailed Description

In the following description, embodiments of the present disclosure will be described by way of example only with reference to a representative design of capsule 1 as shown in Figure 1 . However, the present disclosure is not limited to use with capsules of the particular design shown in Figure 1 .

The example capsule of Figure 1 comprises a cup-shaped body 2 and a lid

3.

The cup-shaped body 2 is formed from a polymeric material as a single, unitary injection moulding. Examples of suitable material for forming the cup- shaped body 2 include polyolefins, including thermoplastic polyolefins. In one example the cup-shaped body 2 is formed from a material comprising

polypropylene and/or polyethylene.

The cup-shaped body 2 comprises a base 5, forming an inlet end of the capsule 1 , a side wall 4 extending away from the base 5 and an outwardly- extending flange 6 at an end of the side wall 4 distal the base 5. A sealing element 7 may be provided on the flange 6. In the illustrated example, the sealing element 7 takes the form of an integral circumferential rib protruding from the surface of the flange 6.

The lid 3, which may be formed from a suitable material such as aluminium foil, a polymeric laminate or a combination thereof, is adhered or otherwise sealed to the flange 6 so as to close the cup-shaped body 2 to define an interior 8 of the capsule which in use can be packed with an extractable beverage ingredient such as roasted ground coffee, tea, etc.

In accordance with the present disclosure, and common to each of the embodiments described in more detail below, the cup-shaped body 2 is subjected to a source of radiant energy in the form of a laser, after its formation by, for example, injection moulding. The application of the laser results in the formation of a plurality of laser-formed features 60 in the base 5.

In the illustrated embodiments the location of the laser-formed features 60 is confined to an annular zone 30 of the base 5, as shown in Figure 4. The annular zone 30 of the cup-shaped body 2 encompass those one or more points of the cup-shaped body 2 which are intended, in use, to be pierced by the beverage preparation machine in which the capsule 1 is used. The location and size of the annular zone 30 may vary depending on the design of the inlet piercing arrangement of the beverage preparation machine. For example, a schematic representation of one type of inlet piercing arrangement is shown in Figures 2 and 3. In these figures only a portion of the beverage preparation machine is shown and this is shown schematically for ease of understanding. As shown, an upper enclosing member 10 of the beverage preparation machine is provided which has a base wall 12 from which the inlet piercing arrangement in the form of a perforation element having three piercers 13 extends. In addition, the upper enclosing member 10 comprises a circumferential side wall 1 1 which terminates at an annular rim 14.

In this illustrated example, the three piercers 13 are located in a circular arrangement around a nominal central longitudinal axis of the upper enclosing member 10. Consequently, in use the base 5 of the capsule 1 will be pierced at three points which lie in a circular arrangement around a central longitudinal axis of the capsule 1 . Consequently, the annular zone 30 for this example may be considered to be a single annular piercing zone as shown in Figure 4 which encompasses each of the three locations that will be contacted and pierced in use by the piercers 13 of the beverage preparation machine whatever the rotational orientation of the capsule 1 about its longitudinal axis. It can be noted that in use not all of the material of the annular zone 30 need be pierced by the piercers 13.

The laser-formed features 60 provided in the base 5 comprise through apertures 61 and/or blind apertures 62. Figures 6 to 8 illustrate three example patterns of laser-formed features 60. In the illustrated examples the blind apertures 61 extend inwardly from an outer surface of the base 5. Alternatively, they may extend from the inner surface of the base 5.

The plurality of laser-formed features 60 as shown in the examples are arranged in the annular zone 30 of the base 5 with a remainder of the base 5 outside said annular zone 30 being free of laser-formed features 60.

Each illustrated example pattern comprises a first circumferential array 63 of laser-formed features extending around the central axis of the capsule 1 .

The patterns of Figures 6 and 7 in addition comprise a second

circumferential array 64 of laser-formed features which is concentric to the first circumferential array 63.

The patterns may also comprise a plurality of transverse arrays 65 of features extending from the first circumferential array 63. In the example of Figure 8 the transverse arrays 65 extend radially outwards of the first

circumferential array 63 and the transverse arrays 65 are radially aligned. In an alternative arrangement the transverse arrays 65 may extend radially inwardly from the first circumferential array 63. In the case of the example of Figures 7 and 7a, the transverse arrays 65 extend between the first circumferential array 63 and the second circumferential array 64. The transverse arrays are angled relative to the radial direction so as to define a reticulated pattern of triangular forms 66 in the base 5.

The plurality of laser-formed features 60 may define a pattern comprising vertexes 67 formed as through apertures 61 and links 68 formed as blind apertures 62. This is the case in the examples of Figures 7 and 8 where the vertexes 67 of the pattern are formed as round through apertures 61 and the links 68 extending between the vertexes 67 are formed as elongate blind apertures 62. It should be noted that the links 68 do not need to extend all the way between the vertexes 67 as shown, for example in Figure 7a, but may stop short of the vertexes 67 to leave a small gap therebetween. In the case of the example of Figure 6 the pattern comprises arrays of round through apertures 61 without links.

The through apertures 61 may each have a maximum critical dimension of

500 microns, preferably a maximum critical dimension of 300 microns, more preferably a maximum critical dimension of 100 microns. For round through apertures 61 , the maximum critical dimension is the diameter of said round through holes, whereas for through apertures 61 comprising elongate holes, each elongate hole having a length greater than its width, the maximum critical dimension is the width of said elongate holes.

The blind apertures 62 may each have a maximum critical dimension of 500 microns, preferably a maximum critical dimension of 300 microns, more preferably a maximum critical dimension of 100 microns. As above for round blind apertures the critical dimension is the diameter and for elongate blind apertures the critical dimension is the width.

The plurality of laser-formed features 60 preferably comprises greater than 50, preferably greater than individual through apertures 61 and/or blind apertures 62. A maximum distance between adjacent through apertures 61 and/or blind apertures 62 is 3000 microns, preferably 1000 microns, more preferably 500 microns, most preferably 100 microns. It will be appreciated that a great variety of patterns of the laser-formed features 60 can be used without departing from the scope of the present disclosure.

The base 5 of the capsule 1 may typically have a thickness in the range 0.20 to 0.50mm, more typically in the range 0.30 to 0.40mm. In one example the thickness is 0.35 to 0.38mm. The thickness of the base 5 may vary across the extent of the base 5 or may alternatively be uniform.

The capsule 1 is sized and configured to be received within the upper enclosing member 10.

As noted above, the plurality of laser-formed features 60 are created after moulding of the cup-shaped body 2 by application of a laser. Preferably, the laser may be focussed as a beam only on the locations where the laser-formed features 60 are to be formed.

The apparatus illustrated schematically in Figure 5 depicts an example of a beam steering laser apparatus that may be used. In beam steering laser treatment the laser beam 51 is steered using two galvanometer-operated mirrors to trace out the required treatment area. Thus use of a mask is not essential (although an interposed mask can be used as well if desired).

For beam steering laser treatment the laser may be a Nd:YAG

(Neodymium doped Yttrium Aluminium Garnet) laser with a wavelength of

1064nm (infrared light) or a doubled Nd:YAG laser with a wavelength of 532 nm (green light). The laser power is typically in the range 2.5-10W for a Nd:YAG laser and 1 -3W for a doubled Nd:YAG laser. To beneficially produce ablation of the polymer material it is typical to use high pulse rate frequencies in the range 1 to 50kHz. An alternative is to use a CO2 laser. An example of a suitable apparatus is the Firestar v40 CO2 laser, coupled to a FH Flyer Marking Head, both available from Synrad, Inc. of Mukilteo, WA, USA. The v40 laser has an output power of 40W and the power may be modulated. The FH Flyer Marking Head may be configured with an 80mm Focusing lens to provide a marking field size of 27mm x 27mm. Using such an arrangement it has been found that formation of through apertures in a piece of HDPE of thickness 0.35mm may be produced using a laser power setting of 30% on the v40 laser and a duration of 6ms. Further, it has been found that formation of blind apertures in a piece of HDPE of thickness 0.35mm may be produced using a laser power setting of 20% on the v40 laser and a duration of 6ms. It will be appreciated that for other thermoplastic polymers and/or different thicknesses the desired aperture may be 5 produced by varying the power setting of the laser source and/or the beam

duration.

Different polymer materials have differing responses to laser treatment. Even with the same polymer, different grades and different colours of polymer can respond differently to the laser radiation. Consequently, one or more

0 additives can be added to the polymer material to improve is suitability for laser treatment. For example, additives such as carbon black, graphite and doped-tin dioxide may be added. One example is the Mark-it™ Laser Marking Pigment produced by BASF Corporation which contains an antimony-doped tin oxide pigment. Typically, the additive in the polymer acts as an element that readily5 absorbs the laser radiation and generates heat which then affects the

surrounding polymer matrix. Thus, even polymers which might otherwise be 'transparent' to radiation at the wavelength of the laser source can be treated.

Use of a laser to form the laser-formed features 60 in the polymer may have the added advantage that the polymer material beneath the laser is o displaced either side of the through apertures 61 and/or blind apertures 62 that the laser is creating. For example, as shown in Figure 9a, when a blind aperture 62 (whether an elongated or round aperture) is formed, the displaced material forms an up-stand 70 of material on each edge of the blind aperture 62 so as to create a strengthening rib around the blind aperture 62. In addition, for blind5 apertures 62, the laser-formation process has been found to create a stress

raiser at the base of the blind aperture 62.

Similarly, as shown in Figure 9b, an up-stand 70 of material may be formed around through apertures 61 (whether elongate or round).

In use the capsule 1 is inserted into the beverage preparation machine o and the upper enclosing member 10 is moved from a position generally of that shown in Figure 2 to a position as shown in Figure 3 in which the upper enclosing member 10 has been moved relative to the capsule 1 such that the annular rim 14 seals against the flange 6 of the capsule 1 . (For ease of reference, the lower enclosing member and its associated outlet piercing arrangement of the beverage preparation machine which pierces the lid 3 has been omitted from the figures). In so doing, the sealing element 7 may contribute to the integrity of the seal so formed. As can be seen from Figure 3, the movement of the upper enclosing member 10 causes the piercers 13 to contact and pierce the polymeric material of the base 5 of the capsule 1 . The piercing of the base 5 allows for ingress of water into the interior 8 to form a beverage from interaction with beverage ingredients held in the capsule 1 . The beverage is then output via apertures formed in the lid 3 by the outlet piercing arrangement of the beverage preparation machine.

During the piercing of the base 5 contact of the piercers 13 may form openings by transforming one or more of the blind apertures 62 in the base 5 into through apertures by stretching and/or tearing and/or cracking of the polymer material at or near the blind apertures 62. In addition, or alternatively, the piercers 13 may form openings by increasing the size of one or more of the pre-formed through apertures 61 by stretching and/or tearing and/or cracking of the polymer.

Flap portions and/or hinged portions may be created by cracks and/or tears encompassing multiple of the laser-formed features 60. For example, in the pattern of Figure 7, a crack and/or tear propagating around a triangular form of the pattern from vertex 80 along link 81 to vertex 82 and then on via link 83 to vertex 84 will create a flap that is able to be deflected inwardly into the cup- shaped body 2 about a basal hinge 85 linking the flap portion to the remainder of the base 5.

Figure 10 shows a graph of the force exerted on two sample capsules by a moving piercer. It illustrates how piercing of the capsule of the present disclosure having a plurality of laser-formed features is improved compared to a standard capsule not having any laser-formed features. Capsule A is the standard capsule having no laser-formed features and Capsule B is the capsule as shown in Figure 6 having a plurality of laser-formed features 60. Other than for the presence or absence of the laser-formed features 60 the design and materials of the two capsules were the same. During the test a piercer from a beverage preparation machine was attached to an extensometer and each capsule was oriented in turn in-line with the piercer replicating the brewing action. The piercer was moved towards the capsule and upon contact with the capsule base was pushed 4mm (shown on the horizontal axis) beyond/into the capsule surface. The force registered in doing so was recorded.

The results show that for Capsule B significantly less force is required to pierce the base. From examination of the capsule after the test, it was noted that the laser-formed features 60 in the capsule meant that the plastic in the piercing region could be stretched and opened up more easily.

In the present description the disclosure has been described by way of example only with reference to the design of machine-insertable beverage capsule 1 shown in the attached Figures. A number of alternatives will be understood to be within the scope of the disclosure as set out in the appended claims.

For example, it has been described that the cup-shaped body 2 may comprise a sealing element 7 in the form of a circumferential rib protruding from the surface of the flange 6. However, other forms of sealing element may also be provided either on the flange 6 or on other portions of the cup-shaped body 2, such as the base 5 or side wall 4. For example the sealing element 7 may take the form of a plurality of ridges, a step formation, an inclined surface or similar geometric form which achieves the necessary sealing interface with the upper enclosing member of the beverage preparation machine.

For example, while the description has described the cup-shaped body 2 being formed from a single unitary moulding, the cup-shaped body 2 may be formed from more than one piece and may be formed by methods other than injection moulding. In addition, the cup-shaped body 2 may be formed from two or more different materials. For example, it may be formed as a co-moulding of two different polymeric materials.

For example, in the attached Figures the capsule has been shown in schematic form and in particular, the cup-shaped body 2 has been shown in a simplified manner showing simply the base 5, side wall 4 and an outwardly extending flange 6. However, other features may be present as part of the cup- shaped body 2 as well known in the art. For example one or more reinforcing structures may be provided, for example ridges or ribs for strengthening the structure of the cup-shaped body 2. The capsule 1 may also be provided with an internal filter at or near the inlet end of the base 5 and/or the outlet end of the lid 3.

For example, in the above description, the beverage preparation machine is provided with three piercers 13 which pierce the base 5 along an annular or circular path around the longitudinal axis of the capsule 1 . The reader will understand that a wide range of other piercing arrangements can be

contemplated. Consequently, an equally wide range of patterns of laser-formed features can be contemplated.

For example, in the above description, the capsule 1 has been described having a lid 3 which in use is torn or pierced by a lower enclosing member of the beverage preparation machine. However, the capsule 1 may take other forms, for example wherein the outlet of the capsule is formed as a pre-pierced or porous sheet or wall which is not intended to be pierced or torn by the lower enclosing member of the beverage preparation machine in use.

Claims

Claims:

1 . A machine-insertable beverage capsule comprising a cup-shaped body and a lid;

the lid being sealed to the outlet end of the cup-shaped body;

the capsule containing one or more extractable beverage ingredients and being suitable for insertion into a beverage preparation machine to permit a pressurised liquid to be flowed through the capsule in order to produce a beverage from interaction with the extractable beverage ingredients;

- through apertures; and/or

- blind apertures.

2. A machine-insertable beverage capsule as claimed in claim 1 , wherein the plurality of laser-formed features are sized and spaced relative to each other to promote formation of one or more elongated openings in the base on closure of the enclosing member by means of crack propagation between adjacent laser- formed features.

3. A machine-insertable beverage capsule as claimed in claim 2, wherein the one or more elongated openings define a flap portion of the base which may be deflected inwardly into an interior of the capsule on closure of the enclosing member.

4. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features comprises greater than 50, preferably greater than 00 individual through apertures and/or blind apertures.

5. A machine-insertable beverage capsule as claimed in any preceding claim, wherein a maximum distance between adjacent through apertures and/or blind apertures of the plurality of laser-formed features is 3000 microns, preferably 1000 microns, more preferably 500 microns, more preferably 100 microns.

6. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features comprises at least one circumferential array of features extending around a central axis of the capsule; and optionally the plurality of laser-formed features comprises a plurality of transverse arrays of features extending from the circumferential array.

7. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features comprises two or more circumferential arrays of laser-formed features; and optionally the machine- insertable beverage capsule further comprises a plurality of transverse arrays of laser-formed features extending between the two or more circumferential arrays of laser-formed features.

8. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features form a reticulated pattern extending circumferentially around a central axis of the capsule.

9. A machine-insertable beverage capsule as claimed in claim 8, wherein the reticulated pattern comprises triangular forms.

10. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features are arranged in an annular zone of the base, said annular zone being centred on a central axis of the capsule and said annular zone at least encompassing that portion of the base intended to be contacted in use by the perforation element of the beverage preparation machine; and optionally a remainder of the base outside said annular zone is free of laser-formed features.

1 . A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features define a pattern comprising vertexes formed as through apertures and links formed as blind apertures.

12. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the through apertures each have a maximum critical dimension of 500 microns, preferably a maximum critical dimension of 300 microns, more preferably a maximum critical dimension of 100 microns.

13. A machine-insertable beverage capsule as claimed in claim 12, wherein the through apertures comprise a plurality of round through holes, wherein the maximum critical dimension is the diameter of said round through holes.

14. A machine-insertable beverage capsule as claimed in claim 12 or claim 13, wherein the through apertures comprise a plurality of elongate holes, each elongate hole having a length greater than its width, wherein the maximum critical dimension is the width of said elongate holes.

15. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the blind apertures each have a maximum critical dimension of 500 microns, preferably a maximum critical dimension of 300 microns, more preferably a maximum critical dimension of 100 microns; and optionally the blind apertures comprise a plurality of round blind holes, wherein the maximum critical dimension is preferably the diameter of said round blind holes.

16. A machine-insertable beverage capsule as claimed in claim 15, wherein the blind apertures comprise a plurality of elongate blind holes, each elongate blind hole having a length greater than its width, wherein the maximum critical dimension is the width of said elongate blind holes.

17. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features comprises a plurality of through apertures and a plurality of blind apertures.

18. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features comprises one or more arrays comprising through apertures interlinked by blind apertures.

19. A machine-insertable beverage capsule as claimed in any preceding claim, wherein the plurality of laser-formed features comprises one or more arrays comprising round apertures (through and/or blind) interlinked by elongate apertures (through and/or blind).

20. A machine-insertable beverage capsule as claimed in any preceding claim, wherein at least the portion of the base designed to be pierced in use is formed of a material comprising a polyolefin, preferably a thermoplastic polyolefin, for example polypropylene and/or polyethylene; and optionally the cup-shaped body is a unitary moulding, and optionally an injection-moulding.

21 . A machine-insertable beverage capsule as claimed in any preceding claim, wherein the flange of the cup-shaped body further comprises a sealing member configured to form a sealing engagement with an enclosing member of a beverage preparation machine to thereby prevent or limit a by-pass flow of water in use.

22. A cup-shaped body for forming a capsule as claimed in any preceding claim.

23. A beverage producing system comprising:

a machine-insertable beverage capsule as claimed in any preceding claim; and

a beverage preparation machine;

24. A method of preparing a beverage comprising the steps of:

- providing a machine-insertable beverage capsule as claimed in any of claims 1 to 21 ;

- providing a beverage preparation machine having an enclosing member and a perforation element;

- positioning the enclosing member in an open position;

- inserting the capsule into the beverage preparation machine;

- wherein during closure of the enclosing member the perforation element interacts with the base of the capsule to form one or more elongated openings in the base by means of crack propagation between adjacent Iaser-formed features of the capsule;

- flowing a pressurised liquid into the one or more elongated openings and through the capsule to produce a beverage from interaction with the beverage ingredients; and - outputting the beverage for consumption.

25. A method as claimed in claim 24, wherein the one or more elongated openings define a flap portion of the base which is deflected inwardly into an interior of the capsule on closure of the enclosing member.

26. A method of producing a cup-shaped body of a machine-insertable beverage capsule, the cup-shaped body comprising a side wall, a base at an inlet end of the cup-shaped body and a flange at an outlet end of the cup-shaped body;

the method comprising the steps of:

first forming the cup-shaped body from a polymeric material;

subsequently, post-moulding, forming with a laser a plurality of through apertures and/or blind apertures in the base.

27. A method as claimed in claim 26, wherein the plurality of laser-formed features are formed in an annular zone of the base, said annular zone being centred on a central axis of the capsule and said annular zone at least

encompassing that portion of the base intended to be contacted in use by the perforation element of the beverage preparation machine; and optionally a remainder of the base outside said annular zone is left free of laser-formed features.

28. A method as claimed in any of claims 26 to 27, wherein the plurality of laser-formed features are formed to have at least one circumferential array of features extending around a central axis of the capsule; and optionally the plurality of laser-formed features are formed to have a plurality of transverse arrays of features extending from the circumferential array.

29. A method as claimed in any of claims 26 to 28, comprising forming with the laser greater than 50, preferably greater than 100 individual through apertures and/or blind apertures in the base of the cup-shaped body.

30. A method as claimed in any of claims 26 to 29, wherein a maximum distance between adjacent through apertures and/or blind apertures is 3000 microns, preferably 1000 microns, more preferably 500 microns, more preferably 100 microns.

31 . A method as claimed in any of claims 26 to 30, the method further comprising forming with the laser a plurality of through apertures and a plurality of blind apertures.