Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
  • B65D85/70—Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for
  • B65D85/804—Disposable containers or packages with contents which are mixed, infused or dissolved in situ, i.e. without having been previously removed from the package
  • B65D85/8043—Packages adapted to allow liquid to pass through the contents
  • B65D85/8046—Pods, i.e. closed containers made only of filter paper or similar material

Definitions

• the present invention in some embodiments thereof, relates to a single use capsule for preparation of a beverage with a beverage production machine and, more particularly, but not exclusively, to a capsule composed of aluminum sheet.
• Capsules of this type generally include a body containing the compacted ground coffee and/or other ingredients and a membrane such as aluminum foil that seals the capsule body.
• the capsule body is shaped as an acute truncated cone with a rim, and the membrane is attached to the rim.
• the body of the capsule is typically made from either aluminum or plastic.
• the inside of the capsule is typically coated with a thin layer of a thermoplastic material that is used to thermo-seal the membrane to the rim and to provide a barrier between the aluminum and content of the capsule.
• the membrane includes a similar coating and/or lacquer.
• the capsule During use in an "espresso" machine, the capsule is placed in a chamber where it is typically pierced on two opposing faces and hot water is passed though the capsule at relatively high pressure and temperature, thereby extracting the aromatic constituents from the ingredients to produce the beverage.
• the rim of the capsule is pressed against a capsule holder to form a sealed engagement.
• the sealed engagement with the capsule holder is typically used to insure that all of the hot water is passed through the capsule for preparation of the coffee beverage and to prevent leakage around the capsule.
• the capsule includes a body having the general shape of an acute truncated cone with a rim and a membrane positioned over the rim to seal the capsule body. It is described that the body of the capsule is composed of aluminum sheet between 60 and 110 micrometers thick, preferably 80 micrometers with the membrane composed of aluminum, preferably between 30 and 60 micrometers thick.
• the capsule is configured for insertion in a beverage production device in order to have a liquid under pressure enter the capsule and interact with the ingredients in the capsule.
• the capsule comprises a base body and a foil member closing the base body by being attached to a flange-like rim extending from the side wall of the base body of the capsule.
• the base body of the capsule comprises a resilient sealing member, the sealing member being designed to be in sealing engagement with an enclosing member of the beverage production device. The sealed engagement assures that all liquid flow is through the interior of the capsule during preparation of the beverage.
• a capsule including a capsule body composed of sheet material that includes at least two structural layers of material.
• the capsule body is additionally coated on its inner surface with an additional layer of polymer, e.g. a thin powder or lacquer coating of polymer.
• one of the layers is formed from aluminum sheet and other layer is formed from a polymer.
• the polymer layer constitutes an outer layer of the capsule body and/or is external with respect to the layer of aluminum sheet.
• the polymer is deformable and/or elastic and is suitable for providing a sealed engagement with an enclosing member of a beverage production machine.
• the sealed engagement insures that during preparation of a beverage all the liquid passes through the capsule and does not leakage around the capsule.
• the polymer layer is suitable for providing thermal insulation during beverage preparation.
• An aspect of some embodiments of the present invention provides for a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule including a capsule body that is formed from aluminum sheet coated with a thermoplastic layer, wherein the thermoplastic layer is coated on a surface of the aluminum sheet that forms an outer surface of the capsule body and wherein the thermoplastic layer has a thickness between 80-300 micrometers.
• thermoplastic material is a thermoplastic elastomer.
• thermoplastic layer is thermoplastic plastomer.
• an inner surface of the capsule body is coated with a thermoplastic heat-sealable polymer.
• the inner coat has a thickness between 20-50 micrometers.
• the aluminum sheet has a thickness between 60 and 110 micrometers.
• the outer surface of the aluminum sheet is painted.
• thermoplastic layer is painted on a surface of the thermoplastic layer opposite a surface facing the aluminum sheet.
• the capsule includes a membrane for sealing the capsule body, wherein the membrane is formed from an aluminum foil and wherein an inner surface of the membrane is coated with a thermoplastic heat-sealable coat.
• the capsule body has a shape of a truncated cone with a rim.
• the aluminum sheet is laminated with the thermoplastic layer prior to forming the shape of the capsule body.
• the shape of the capsule body is formed by drawing.
• An aspect of some embodiments of the present invention provides for a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule including a capsule body that is formed from aluminum sheet including an inner surface and an outer surface, wherein the outer surface is coated with paint and the paint is further coated with a transparent polymer layer.
• the polymer is a thermoplastic material.
• the inner surface of the capsule body is coated with a thermoplastic heat-sealable polymer.
• the inner coat has a thickness between 20-50 micrometers.
• the aluminum sheet has a thickness between 60 and 110 micrometers.
• the capsule includes a membrane for sealing the capsule body, wherein the membrane is formed from an aluminum foil and wherein an inner surface of the membrane is coated with a thermoplastic heat-sealable coat.
• the capsule body has a shape of a truncated cone with a rim.
• the aluminum sheet is coated with the paint prior to forming a shape of the capsule body.
• the shape of the capsule body is formed by drawing.
• An aspect of some embodiments of the present invention provides for a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule including a capsule body that is formed from aluminum sheet coated with a polymer layer, wherein the polymer layer is coated on a surface of the aluminum sheet that forms an outer surface of the capsule body and wherein the polymer layer has a thickness between 80-300 micrometers.
• the polymer layer is thermoplastic elastomer.
• the polymer layer is thermoplastic plastomer.
• an inner surface of the capsule body is coated with a thermoplastic heat-sealable lacquer.
• the inner coat has a thickness between 20-50 micrometers.
• the aluminum sheet has a thickness between 60 and 110 micrometers.
• the outer surface of the aluminum sheet is painted.
• the capsule includes a membrane for sealing the capsule body, wherein the membrane is formed from an aluminum foil and wherein an inner surface of the membrane is coated with a thermoplastic heat-sealable coat.
• the capsule body has a shape of a truncated cone with a rim.
• An aspect of some embodiments of the present invention provides for a method for producing a capsule body of a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule including a capsule body, the method comprising: coating a first surface of an aluminum sheet with a polymer layer of thickness between 80-300 micrometers; and drawing a shape of the capsule body with the aluminum sheet that is coated with the polymer layer, wherein the polymer layer forms an outer surface of the capsule body.
• the polymer layer is thermoplastic elastomer.
• the polymer layer is thermoplastic plastomer.
• the method includes coating a second surface of the aluminum sheet with a thermoplastic heat-sealable coat prior to drawing the shape of the capsule, wherein the thermoplastic heat-sealable coat forms an inner surface of the capsule body.
• the coat has a thickness between 20-50 micrometers.
• the capsule body is sealed with a membrane of foil including an inner layer of thermoplastic heat-sealable coat.
• the aluminum sheet is coated with the polymer layer using a lamination technique.
• the aluminum sheet is coated with the polymer layer using a dry powder coating.
• An aspect of some embodiments of the present invention provides for a method for producing a capsule body of a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule including a capsule body, the method comprising: drawing a shape of the capsule body with an aluminum sheet; and coating an outer surface of the capsule body with a polymer layer of thickness between 80-300 micrometers.
• the aluminum sheet is coated with the polymer layer using fluidized bed and powder coating process.
• the method includes applying a thermoplastic heat-sealable coat on an inner surface of the capsule body.
• the coat is applied prior to drawing the shape of the capsule.
• FIGs. 1A and IB are simplified schematic perspective and cross- sectional views of a capsule made with a double layer of material and an internal coating in accordance with some embodiments of the present invention
• FIG. 2 is a simplified schematic cross sectional view of an exemplary capsule placed in an enclosing member of a beverage production machine in accordance with some embodiments of the present invention
• FIG. 3 is a simplified flow chart of an exemplary method for forming sheet material with lamination for use in producing a capsule body in accordance with some embodiments of the present invention
• FIG. 4 is a simplified flow chart of an exemplary method for forming sheet material with extruded lamination for use in producing a capsule body in accordance with some embodiments of the present invention
• FIG. 5 is a simplified flow chart of an exemplary method for forming sheet material with coating for use in producing a capsule body in accordance with some embodiments of the present invention.
• FIG. 6 is a simplified flow chart of an exemplary method for adding a polymer layer subsequent to forming a capsule body shape in accordance with some embodiments of the present invention. DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION
• the present invention in some embodiments thereof, relates to a single use capsule for preparation of a beverage with a beverage production machine and, more particularly, but not exclusively, to a capsule composed of aluminum sheet.
• a capsule body is composed of a layer of aluminum sheet and a layer of polymer.
• the layer of polymer is laminated on the aluminum sheet.
• a powder coating, by fluidized bed coating process is used for applying the layer of polymer on the aluminum sheet.
• the polymer layer is formed with an elastomer, a polymer with elastic properties and/or a polymer that is deformable.
• the polymer layer has a hardness of between 60-95 Shore A.
• the layer of aluminum sheet has a thickness of between 60-110 micrometers and the layer of polymer has a thickness of between 80-300 micrometers.
• the polymer layer is defined to be thicker than the aluminum sheet.
• the polymer layer e.g.
• 80-300 micrometers is layered on a first surface of the aluminum sheet while a second oppositely facing surface of the aluminum sheet is coated with a thin coating of polymer and/or lacquer e.g. that has a thickness of 20-50 micrometers, e.g. 30 micrometers and/or is significantly thinner than the polymer layer.
• the first surface is coated with a thin coating of paint prior to adding the thick polymer layer.
• the polymer layer that is added to the first surface of the aluminum sheet operates as a structural component of the capsule body, e.g. increases the rigidity and strength of the capsule body due to its defined thickness and elastic modulus.
• the aluminum layer is used to protect content stored in the capsule against ingress of moisture, oxygen and UV radiation and the thick polymer layer is used to provide additional rigidity to the structure of the capsule body.
• the additional rigidity provides for using a thinner layer of aluminum sheet and thereby reducing cost of material.
• the thick polymer layer additionally functions as a thermal insulator to prevent heat loss through the capsule body during preparation of the beverage.
• the present inventors have found that the heat loss that typically occurs through capsule formed from aluminum sheet when hot water is introduced into the capsule is significant and adversely affects the quality of the prepared beverage.
• qualities of hot beverages prepared with beverage production machines can be improved by maintaining high temperatures and pressures during preparation.
• internal pressure in the capsule is a main driver for the creation of foam and/or "crema" in coffee.
• “Crema” is typically important for consumers as it provides controlled aroma release as well as for its own mouth feel.
• the present inventors have found that by adding a polymer layer to the capsule, higher temperatures and pressures can be maintained within the capsule during preparation of the beverage.
• the thick polymer layer additionally enables sealed engagement with the beverage production machine without requiring introducing a dedicated sealing member on the capsule and/or on a surface of the beverage production machine that engages the capsule.
• the capsule is formed by first producing a multi-layered material and then shaping the material into the capsule body.
• drawing and/or deep drawing is used for forming the capsule's geometrical shape.
• the aluminum sheet is coated with one or more additional layers prior to forming the capsule's geometrical shape e.g. coated with paint and/or a primer.
• the polymer layer is only applied after the capsule's geometrical shape has been formed.
• a capsule 200 includes a capsule body 100 defining a volume for containing a product and a rim and/or flange 140 over which a membrane 150 is attached for sealing capsule body 100.
• capsule body 100 is shaped as an acute truncated cone.
• capsule body 100 is composed of an inner layer of aluminum sheet 120 and an outer layer of polymer 110.
• aluminum sheet layer 120 has a thickness of between 60-110 micrometers and polymer layer 110 has a thickness of between 80-300 micrometers.
• polymer layer 110 is defined to be thicker than aluminum sheet layer 120.
• polymer layer 110 increases structural stability and/or rigidity of capsule body 100 so that a thinner layer of aluminum sheet, e.g. less than 80 micrometers can be used.
• a thinner layer of aluminum sheet 120 reduces cost of materials.
• polymer layer 110 is a layer of thermoplastic polymer such as polyethylene (PE), polypropylene (PP), polyamide (PA) and Polyethylene terephthalate (PET) or a thermoplastic elastomer (TPE), a blend of thermoplastic polymers and thermoplastic elastomers, or plastomer.
• PE polyethylene
• PP polypropylene
• PA polyamide
• PET Polyethylene terephthalate
• TPE thermoplastic elastomer
• polymer layer 110 is transparent.
• polymer layer 110 is translucent, opaque and/or colored.
• polymer layer 110 is an elastomer and/or a polymer that is deformable under pressure.
• the deformable and/or elastic properties of polymer layer 110 provides for establishing a fluid seal when engaging an enclosing member of a beverage production machine on capsule 200.
• an outer surface 133 of aluminum sheet layer 120 is painted prior to applying polymer layer 110.
• membrane 150 is composed of an aluminum foil that is between 30 and 60 micrometers thick.
• an inner surface 130 of aluminum sheet layer 120 and inner surface 131 of membrane 150 are coated with a polymer coating or lacquer 125, e.g. a thermoplastic lacquer.
• polymer coating or lacquer 125 provides for thermo- sealing membrane 150 to flange 140.
• FIG. 2 showing a simplified schematic cross sectional view of an exemplary capsule placed in an enclosing member of a beverage production machine in accordance with some embodiments of the present invention.
• capsule 200 is positioned between a capsule holder 413 and an enclosing member 409 of a beverage production machine so that membrane 150 of capsule 200 rests on capsule holder 413.
• enclosing member 409 includes an annular support skirt 418 that presses against polymer layer 110 of flange 140.
• pressure applied by enclosing member 409 deforms polymer layer 110.
• deformation of polymer layer 110 results in sealed engagement between enclosing member 409 and capsule 200.
• water inlet opening 420 feeds liquid, e.g. hot water under pressure to a water injector 414 that penetrates through capsule 200.
• enclosing member 409 does not include water injector 414 and fluid is introduced into capsule 200 directly from water inlet opening 420 after perforating capsule body 100.
• pressure inside the capsule exceeds a certain threshold value, membrane 150 bulges toward relief elements 412 causing local rupture of membrane 150. Rupture of membrane 150 releases the prepared beverage.
• sealed engagement between enclosing member 409 and capsule 200 prevents liquid introduced through inlet opening 420 and flowing around outer walls of capsule 200, from leaking around flange 140.
• polymer layer 110 provides heat insulation for maintaining high temperatures and pressure in capsule 200 while a hot water is injected into capsule 200.
• polymer layer 110 reduces heat loss that would otherwise occur across aluminum sheet layer 120.
• the present inventors have found that a polymer layer of at least 80 micrometers typically required for thermal insulation.
• capsule body 100 is formed from a coated and laminated aluminum sheet.
• a roll of aluminum sheet and/or foil is unwound (block 310) and advanced to a coating station for coating one surface of the sheet with lacquer coating or polymer powder coating (block 315).
• the aluminum sheet has a thickness of between 60-110 micrometers and the thin polymer coating of 30 micrometers is applied.
• the coated surface is used to form inner surface 130 of capsule 200 (FIG. IB).
• an adhesive and/or primer is applied on another, e.g. opposing surface of the aluminum sheet (block 320) and then a plastic film is laminated on this opposing surface e.g. the surface with the adhesive and/or primer, e.g. (block 325).
• the plastic film has a thickness of between 80-300 micrometers.
• the plastic film is a thermoplastic film, or TPE film, or a blend of these two types of materials.
• the plastic film is a plastomer and/or includes a plastomer.
• the laminated aluminum sheet is rolled up (block 330).
• the opposing surface subsequently forms outer surface 133 of aluminum layer 120 in capsule body 100 (FIGs. 1A-1B).
• the opposing surface is painted prior to lamination.
• the coated and laminated aluminum sheet is subsequently used in a deep drawing process to form the shape of the capsule body 100 (block 350).
• the capsule body is shaped as an acute truncated cone with a rim.
• the deep drawing process is a process that is separate from the lamination process.
• FIG. 4 showing a simplified flow chart of an exemplary method for forming sheet material with extruded (cast) lamination for use in producing a capsule body in accordance with some embodiments of the present invention.
• an extruded lamination technique is used instead of a preformed foil lamination technique to form sheet material for constructing capsule body 100.
• the method for forming sheet material with extruded lamination is similar to the method described in reference to FIG. 3 except that the aluminum sheet is laminated by extruding of a plastic film (block 327) instead of lamination with a pre-formed foil of plastic film (FIG. 3).
• heating that occurs during extrusion is enough to adhere the plastic onto the aluminum sheet and the method of applying adhesive or primer on a surface before performing extrusion lamination (block 320) is generally omitted.
• FIG. 5 showing a simplified flow chart of an exemplary method for forming sheet material with coating for use in producing a capsule body in accordance with some embodiments of the present invention.
• coating is used instead of lamination to apply a thick polymer layer on an aluminum sheet.
• the aluminum sheet when a coating technique is applied, the aluminum sheet is unwound (block 310) and advanced to a first coating station for coating one surface of the sheet with lacquer or polymer coating (block 315) and a second coating station for coating another, opposing surface of the sheet with a thick polymer layer (block 317).
• both surfaces are coated in a same coating station, e.g. optionally at the same time.
• a thin coating layer of 30 micrometers is applied during coating on the one surface and a thick coating layer of between 80-300 micrometers is applied on the opposing surface.
• thermoplastic polymer or TPE or a blend of these two types of materials is used for the thick coating.
• a plastomer is used.
• the opposing surface is painted prior to lamination.
• the coated aluminum sheet is wound (block 330).
• the coated aluminum is subsequently used in a deep drawing process to form the shape of the capsule body (block 350).
• the capsule body is shaped so that the thin coating of the aluminum sheet is inside the capsule body and the thick coating is on the outside of the capsule body.
• the capsule body is shaped as an acute truncated cone with a rim.
• the deep drawing process is a process that is independent from the coating process.
• FIG. 6 showing a simplified flow chart of an exemplary method for coating a polymer layer subsequent to forming a capsule body structural shape in accordance with some embodiments of the present invention.
• an aluminum sheet is received (block 340) and a drawing process, e.g. a deep drawing process is used to form a desired structural shape of the capsule (block 350).
• the desired shape is an acute truncated cone with a rim.
• coating is applied on one or more surfaces of the cone after forming its shape (block 360).
• a powder coating, applying fluidized bed coating process is used for coating the capsule.
• curing and/or melting is required after coating (block 370).
• an outer surface of capsule body 100 is coated with 80-300 micrometers layer of polymer, e.g. thermoplastic polymer or TPE or a blend of these two types of materials.
• a plastomer is used.
• an inner surface of capsule body 100 is coated with a thin layer of polymer or lacquer e.g. a 30 micrometers layer.
• the aluminum sheet coated with the thin layer prior to drawing the shape of capsule body 100 is painted prior to drawing the shape of capsule body 100.
• the capsule as described herein is not limited in this respect and can also be used and/or adapted for the preparation of cold beverage including carbonated beverages and/or alcoholic beverages.
• compositions, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Apparatus For Making Beverages (AREA)
• Laminated Bodies (AREA)

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• 2015
  • 2015-08-26 EP EP15778393.7A patent/EP3194301A1/de not_active Withdrawn
  • 2015-08-26 WO PCT/IL2015/050853 patent/WO2016030887A1/en active Application Filing
• 2017
  • 2017-02-28 IL IL250851A patent/IL250851A0/en unknown

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