US20210078794A1

US20210078794A1 - Prepackaged pod for brewing hot beverages and method for producing the same

Info

Publication number: US20210078794A1
Application number: US16/961,457
Authority: US
Inventors: MACRIPO' Giuliano
Original assignee: Individual
Current assignee: Idea SAS Di Next & Co Srl
Priority date: 2017-09-20
Filing date: 2018-09-19
Publication date: 2021-03-18
Also published as: WO2019058274A1; IT201700105336A1

Abstract

A pod to be used in machines for brewing hot beverages. For example, a pod comprises two water-permeable filtering elements coupled to each other along a periphery forming a casing, which contains substances extractable by forced percolation, in which said periphery is sealed and embedded by a sealing flange of the pod that extends continuously around said casing.

Description

TECHNICAL FIELD OF INVENTION

The present invention refers to a prepackaged pod having innovative characteristics. Specifically, the invention refers to a pod to be used in machines for brewing hot beverages, containing substances extractable by forced percolation, preferably such as coffee or possibly other beverages such as for example tea. Further, the invention refers to the method for producing said prepackaged pod.

BACKGROUND OF THE INVENTION

The machines for brewing espresso coffee achieve the extraction of the aromas from the ground coffee by means of forced percolation process.
In this process, water, heated to a temperature of approximately 90° C., is made to flow under pressure, generally between 9 and 15 bar, through the ground coffee contained in a percolation chamber of the dispensing unit of the machine, thereby extracting the beverage.
To simplify the use of espresso coffee machines, prepackaged portions of finely ground roasted coffee are sold to be easily inserted into the coffee machine when they are to be used, and afterward they are removed and treated as waste at the end of the brewing process.
There are currently two main solutions for the preparation of ready-to-use prepackaged portions of coffee, the first of which provides the ground coffee being contained in a capsule whereas in the second solution the coffee is contained in a pod.
The capsule is formed by a rigid casing of substantially cylindrical shape having a height of approximately 26 mm, made of plastic or aluminium, and a cover made of an aluminium sheet that seals the casing. Inside the rigid casing is inserted the predetermined portion of ground coffee that is subjected to the brewing process. There are in fact different types of capsules, having shapes and characteristics that generally depend on the industrial specifications of the manufacturer of each espresso coffee machine.
On the other hand, the pod is a predetermined portion of ground coffee that is enclosed between two sheets of water-permeable filter paper elements, in a generally disk-shaped form having a height of approximately 10 mm that, unlike the capsule, is soft and flexible. There are, in fact, different standards that define the technical and geometrical characteristics of the pods: among them the most widely adopted by manufacturers of coffee brewing machines is ESE (Easy Serving Espresso), which defines some parameters such as the amount of coffee, the shape and the diameter of the pod.
Below are described the advantages of using the pod, compared to the capsule, and the technical problems thereof.
The pod is formed by sheets of filter paper, and for this reason it does not alter the organoleptic properties of the coffee resulting from the brewing process, and therefore the extracted beverage is appreciated for its excellent quality.
By contrast, the capsule, being made of plastic materials, during the extraction phase, as is well known, releases additives contained in it and/or residues from the polymerization process that can alter the organoleptic properties of the coffee and/or are harmful for the human body.
Furthermore, the pod is relatively smaller in height than the capsule, and this makes it possible to maintain a constant efficiency of extraction of the aromas during the forced percolation process, thus avoiding problems of over-extraction and under-extraction due to the change in the temperature of the water during its percolation passage through the ground coffee.
Moreover, the pod is made of biodegradable and compostable materials, unlike the capsule that is generally made of non-biodegradable polymers, and therefore it has a minimal environmental impact, and its disposal is more sustainable compared to the capsule considering the sale volumes of these products and the relative waste that is generated.
However, due to the nature of the pod, made with water-permeable filter paper, in the design phase of the espresso coffee machine, in order to avoid pressure drops during the brewing process, it is necessary to provide suitable sealing systems to hermetically enclose the percolation chamber of the dispensing unit so as to guarantee a correct extraction process.
In other words, the espresso coffee machine that uses the pods, unlike the machine that uses capsules, must be provided with complex systems of levers to apply a strong closing force of the percolation chamber walls so as to hold the peripheral edges of the pod and keep the percolation chamber hermetically closed, with a pressure that during the process is generally between 9 and 15 bar, to avoid the permeation of the water outside the chamber through the edges of the pod.
The mechanical type solutions to this problem require, at present, the application of very high tightening forces which can be obtained with an increased mechanical complexity not suitable for a machine preferably designed for home, or professional use, and that, moreover, leads to increased size and costs of the coffee brewing machine that limit the adoption of this type of machines in, preferably, home or professional applications.
Moreover, due to its nature the pod, being soft and flexible, is difficult to handle during the phase of positioning it inside the coffee machine and, as is evident above, this operation must be performed accurately to guarantee a proper closure of the percolation chamber of the dispensing unit.
Again, because of the problems of handling the pod, all the operations for inserting and removing the pod from the espresso coffee machine are performed manually and cannot be easily carried out automatically, as can be done instead with the capsules; for example, the pod, after being used is removed manually while still soaked with the water used to prepare the beverage.
The mechanical type solutions to this problem would thus require the production of espresso coffee machines having complex handling systems that would result in increases size and machine costs that would limit the spread of this type of machines in, preferably, home or professional applications.
Moreover, as a result of the forces necessarily applied to hermetically close the walls of the percolation chamber, and of the relatively high brewing temperatures, the surfaces of the pod, made with sheets of filter paper, may adhere to the walls of the percolation chamber, prevalently at the closing edges, and could break when they are being removed, thus dirtying the machine.

SUMMARY OF THE INVENTION

The present invention overcomes the technical problems described above, and describes a pod having the innovative characteristics that allow its uncomplicated use in the machines for brewing hot beverages, while also guaranteeing the extraction of a beverage with excellent organoleptic properties.
In the scope of the above task, a first objective concerns the production of a pod configured so as to allow, in the phase of designing the machine, the use of simple mechanical solutions suitable to guarantee the hermetic closure of the percolation chamber of the dispensing unit while applying relatively low tightening forces, and at the same time guarantee the maintenance of the pressures during the forced percolation process.
A second objective of the present invention concerns the production of a pod having a substantially rigid structure suitable to enable its easy handling both when inserting it and removing it from the percolation chamber of the dispensing unit, while allowing the possibility of providing automatic phases, in addition to guaranteeing an uncomplicated cleaning of the machine.
A third objective is to provide a pod made of materials that, during the beverage extraction phase, do not release substances that could affect the taste of the coffee or cause, once swallowed, harmful effects for the user, thus preparing a beverage with excellent organoleptic properties and not contaminated by undesirable substances.
A fourth objective is to provide a pod made of biodegradable materials, of natural origin, and that can preferably be compostable, in accordance with harmonized standards, such as for example EN1 3432, making waste disposal more sustainable and thus decreasing the carbon footprint of the life cycle of substances for the preparation of beverages, for example coffee, aimed for consumption through the preparation of ready-made portions.
A further objective is to realize pods that could individually contain within them an inert gas, such as nitrogen, or that are hermetically vacuum-sealed so as to protect the substances used to prepare the beverage, for example coffee, from environmental agents such as moisture, light and oxygen, and to thus avoid the use of packaging to pack the pod.
Finally, one last objective concerns the definition of a method for making the pods using simple technologies and plants, machines and equipment typical in the field.

BRIEF DESCRIPTION OF THE FIGURES

Further characteristics and advantages of the pod according to the present invention will become more evident in the description which follows, relative to some embodiments given purely by way of example, not limiting, with reference to the following figures, in which:

FIG. 1 is a perspective view of a pod in a first embodiment, according to the present invention.

FIG. 2 is an exploded perspective view of the pod of FIG. 1.

FIG. 3 is a cross-sectional view of the pod of FIG. 1.

FIG. 4 is an exploded side view of the pod of FIG. 1.

FIG. 5 is a cross-sectional view of a machine for brewing hot beverages, containing the pod of FIG. 1.

FIG. 6 is a perspective view of a pod in a second embodiment, according to the present invention.

FIG. 7 is a cross-sectional view of the pod of FIG. 6.

FIG. 8 is a perspective view of a pod in a third embodiment, according to the present invention.

FIG. 9 is an exploded perspective view of the pod of FIG. 8.

FIG. 10 is a perspective view of a pod in a fourth embodiment, according to the present invention.

FIG. 11 is a side view of the pod of FIG. 10.

DETAILED DESCRIPTION OF THE INVENTION

The preferred embodiment of the present invention refers to its use for preparing coffee. This embodiment shall not in any way be understood as a limitation of the field of application of the invention, and it can be applied to any beverage that is obtained by extracting the aromas from one or more substances by means of forced percolation.
With reference to FIGS. 1, 2, 3 and 4, is shown a pod 100, according to the present invention, comprising two water-permeable filtering elements 102 (see FIG. 3), such as sheet of filter paper, substantially identical to each other and preferably of a circular shape having both a common axis A, hereafter called “central axis A” of the pod, perpendicular to the surfaces thereof. The sheet of filter paper is preferably a micropore filter made of abaca fibre, wood pulp and cellulose fibre, or the like. The two sheets of filter paper 102 are coupled to each other along their respective periphery 104 (see FIGS. 2 and 4), which extends radially outward from the axis A of the filtering elements 102, forming a central casing 106.
Said casing 106, containing the ground coffee, has preferably a disk shape, comprising an upper base, a lower base and a thickness defined by the distance between the two bases, and also has an axis perpendicular to its bases, upper and lower, coinciding with the central axis A of the pod 100.
At the upper surface and at the lower surface of the periphery 104 of the two sheets of filter paper 102 are formed, respectively, two rings, the first being the upper ring 108 and the second being the lower ring 110, substantially identical to each other, having a common axis, perpendicular to the planes of each ring, coincident with the central axis A. The radius of the circumference that circumscribes the outer perimeter of the upper ring 108 and of the lower ring 110 (hereafter defined as “outer radius of the ring”) is slightly larger than the radius of the circumference that circumscribes the perimeter of the periphery 104 of the sheets of filter paper 102 (hereafter defined as “radius of the periphery”). Also, the radius of the circumference inscribed in the inner perimeter of the upper ring 108 and of the lower ring 110 (hereafter defined as “inner radius of the ring”) is equal or slightly larger than the radius that circumscribes the casing 106 (hereafter defined as “radius of the casing”).
The upper ring 108 is provided with an annular groove 107, extending continuously on the lower surface of said ring 108, and the lower ring 110 is provided with an annular projection 109, extending continuously on the upper surface of said ring 110, adapted to perfectly engage the annular groove 107, in a shape coupling relationship, when the lower surface and the upper surface, respectively, of the upper ring 108 and of the lower ring 110 are coupled to each other.
Said upper ring 108 and lower ring 110 are preferably formed by injection moulding process, or thermoforming, and preferably are made of biodegradable thermoplastic material, from renewable materials of natural origin, and compostable, such as, preferably, PLA.
PLA is a thermoplastic aliphatic polyester, composed of lactic acid derived from sources of vegetable origin, having thermal and mechanical characteristics, such as stiffness, which, as is well known, are comparable with those of materials such as PP (polypropylene) and PET (polyethylene terephthalate) that are widely used in food packing applications.
In fact, PP and PET, depending on type, have elastic moduli generally included between 1000 and 3000 MPa (ISO1 78), while the elastic moduli of PLA are generally higher than 3000 MPa (ISO1 78). Moreover, suitable selected types of PLA are in compliance with requirements for food contact products, required in this type of application.
The upper ring 108 and the lower ring 110 are joined to each other, by interposing between them the periphery 104 of the two sheets of filter paper 102, by means of a sealing joining process, preferably vibration welding, or heat sealing, gluing with suitable bonding agent, or the like.
The upper ring 108 and the lower ring 110, joined to each other, form a sealing flange 112 of the pod 100 that seals and embeds the periphery 104, and that is also integral with the casing 106 containing the coffee.
FIG. 5 illustrates a percolation chamber 202 of a dispensing unit 200 of an espresso coffee machine, containing the pod 100, in which the sealing flange 112 has a shape such as to perfectly engage the seat of the percolation chamber 202 of the dispensing unit 200 adapted to receive the pod 100. In other words, during the closure of the dispensing unit 200 of the coffee machine, the upper surface and the lower surface of the sealing flange 112 of the pod 100 are adapted to engage the two walls that form the percolation chamber 202, namely the first upper wall 204 and the second lower wall 206, respectively, to close the chamber hermetically.
Thus, during the forced percolation process, the pod 100, placed in its seat inside the dispensing unit 200, is held by the walls, namely the first upper wall 204 and the second lower wall 206, at the sealing flange 112, thereby hermetically closing the percolation chamber 202. In this condition, there is no drop in pressure or leakage of water from the percolation chamber 202 since the sealing flange 112 works as a hermetically-sealed closing element without the need to apply strong closing forces to the walls of the percolation chamber 202. Moreover, there is no likelihood that water permeates through the periphery 104 of the two sheets of filter paper 102, since it is embedded into the sealing flange 112 and does not communicate with the surfaces, which are external to the percolation chamber 202, of the first wall at the top 204 and the second wall at the bottom 206.
Therefore, during the brewing process, the hot water maintains its nominal working pressure constant for a correct extraction of the beverage, and in these conditions it flows through the thickness of the casing 106 of the pod 100, entering first into the percolation chamber 202 through an inflow port 208 and then flowing out of the percolation chamber 202 through an outflow port 210.
The pod 100 described here is innovative, since the periphery 104 is sealed and embedded by the sealing flange 112, which extends continuously around the casing 106, and has a structural stiffness, provided by the sealing flange 112, such as to prevent the two sheets of filter paper 102, forming the casing 106, from bending. Thus, this flange 112 ensures an easy handling of the pod 100 and also an effective hermetic closure of the percolation chamber 202 of the dispensing unit 200, without the need of applying high tightening forces.
In addition, the brewing process takes place by bringing the hot water under pressure substantially into contact with, exclusively, the sheets of filter paper 102 and the ground coffee, in a way similar to what happens when the traditional pods are used, and only a minimal portion of the internal surface of the sealing flange 112 is in contact with the water. Therefore, the organoleptic properties of the coffee are not altered and no harmful substances are released through the effect of the extraction process, thus guaranteeing a product of excellent quality.
Moreover, the nature of the materials used to make the casing 106 and the sealing flange 112, using respectively filter paper and PLA, of natural origin and compostable, makes it possible to have a sustainable disposal of the pod 100, at the end of its life cycle, because it is completely compostable.
Finally, the pod 100, formed as described above, can be inserted in packets that are hermetically vacuum sealed or containing an inert gas, such as gaseous nitrogen, so as to preserve the organoleptic characteristics of the coffee, until the pod is used.
It is clear that different embodiments are possible, with respect to the embodiment described thus far, offering possible solutions with improved performance, without however departing from the scope of patent protection as defined by the claims.
For example, in the previous description the sealing flange 112 is formed by two elements, namely the upper ring 108 and the lower ring 110, but it is possible to provide that said sealing flange 112 is formed with a single element obtained, preferably, through injection processes or the like, such as for example by overmoulding on the periphery 104 of the sheets of filter paper 102.
Below are described further embodiments of the present invention that provide for modifications relative to some of the elements that form the pod 100. Thus, the elements that are essentially unchanged will not be described anew and the same numerical references will be used.
With reference to FIGS. 6 and 7, a pod 100 is shown in a second embodiment substantially the same as the one described above, comprising in addition two shells 114, placed above and below the casing 106 of the pod 100, substantially the same to each other. The shells 114 comprise a base 116 and a portion of countersunk wall 118. The base 116 is perpendicular to the central axis A, and has the radius of the circumference that circumscribes it slightly smaller than the inner radius of the upper ring 108 and of the lower radius 110. The portion of countersunk wall 118 has a height that is substantially at least equal to half of the thickness of the casing 106 of the pod 100, and is formed starting from the perimeter of the base 116, perpendicular to the same, and widens away from the circular base 116 forming a peripheral edge 120, of each of the two shells 114, equal to the internal perimeter of the upper ring 108 and of the lower ring 110 of the pod 100.
The two shells 114 are joined, respectively, at the upper ring 108 and at the lower ring 110 by means of a joint, preferably obtained by vibration welding, injection moulding or heat sealing, between the peripheral edge 120 of each of the two shells 114 and, respectively, the edge of the inner perimeter of the upper ring 108 and of the lower ring 110, thereby forming a sealed chamber 122 that hermetically encloses the casing 106 of the pod 100.
Said joint along the peripheral edge 120 is thin, as compared to the thickness of the shells 114 and of the respective rings, the first or upper one 108 and the second or lower one 110, and represents a breaking point adapted to facilitate the separation of the shells 114 from the respective rings, the upper one 108 and the lower one 110, by a mechanical action, such as a mechanical twisting action applied manually by the user. In this manner, when the shells 114 are removed, the pod 100 is used, for preparing the beverage, in a manner similar to the pod 100 of the first embodiment.
Advantageously, said sealed chamber 122 of the pod 100 contains an inert atmosphere, such as gaseous nitrogen or vacuum, so as to preserve the organoleptic characteristics of the coffee, until the removal of the shells 114. Thus, the pod 100 so composed does not require being packaged in an inert atmosphere, such as gaseous nitrogen or vacuum, since the shells 114 act as barriers against environmental agents, such as moisture, light and oxygen. In addition, the shells 114, being made with the same material as the sealing flange 112, are biodegradable and compostable, and thus they can be disposed as waste in a manner similar to the other components of the pod 100.
With reference to FIGS. 8 and 9, a third embodiment is shown in which the pod 100, substantially equal to the one of the first embodiment, also includes two covers 124, placed above and below the casing 106 of the pod 100, substantially equal to each other. The covers 124 comprise a base 126 and a portion of slightly inclined external wall 128. The base 126 is perpendicular to the central axis A and has the radius of the circumference that circumscribes it slightly smaller than the internal radius of the two rings, namely the first one or upper ring 108 and the second one or lower ring 110. The slightly inclined external wall 128 is formed starting from the perimeter of the base 126, has a height that is substantially at least equal to half of the thickness of the casing 106 of the pod 100, and widens as the distance from the circular base 116 increases, forming a peripheral edge 130, of each of the two covers 124, equal to the internal perimeter of the upper ring 108 and of the lower ring 110.
The two covers 124 are respectively formed integral with the upper ring 108 and the lower ring 110, preferably by means of an injection-moulding, thermoforming or welding process, thus forming a sealed chamber 132 that hermetically encloses the casing 106 of the pod 100.
On the surface of the base 126 of the covers 124 is formed an annular channel 134, having an axis coinciding with the central axis A, which defines a separable portion 136 of the base 126 having a cross section larger than the cross section of the inflow port 208 of the percolation chamber 202 of the coffee machine.
Said channel 134 represents a breaking point adapted to facilitate the separation of the separable portion 136 from the base 126 by mechanical action, such as a pressure applied from outside the pod 100, which occurs during the closure of the percolation chamber 202 of the dispensing unit 200 of the espresso coffee machine, by means of the suitably shaped walls, the first wall, or top one 204, and the second, or bottom one 206.
In this embodiment as in the second embodiment described above, said sealed chamber 132 contains an inert atmosphere, such as gaseous nitrogen or vacuum, so as to preserve the organoleptic characteristics of the coffee, contained in the casing 106, and the covers 124 act as a barrier against environmental agents such as moisture, light and oxygen.
Moreover, this embodiment guarantees ease and speed in the use of the pod 100 since it is not necessary to manually remove the shells 114 before using the pod 100, as in the second embodiment, but the chamber 132 is opened automatically when tightening the percolation chamber 202 of the dispensing unit 200 of the espresso coffee machine which, as it closes, separates the separable portion 136 from the base 126 of the shells 114.
This solution is advantageous in applications whose uses require speedy action, as in automatic beverage dispensing systems, but in which, however, compared with the two preceding embodiments, the hot water under pressure is in contact with the material of the covers 124 and, therefore, in which there could be a slight variation in the organoleptic properties of the coffee.
Additionally, with this solution, by suitably forming the shape of the covers 124, it is possible to further control the process of brewing the beverage from the ground coffee so as to optimize the distribution of the hot water under pressure on the surface of the whole casing 106 containing the ground coffee, including the peripheral areas thereof.
Thus is achieved a greater efficiency in the extraction of the beverage and, consequently, a reduction of the quantity of coffee in the pod 100, with obvious economic advantages.
It should be noted that advantageously, in the second and third embodiments, the structural stiffness of the sealing flange 112 is such as to prevent the flexing of the two sheets of filter paper 102 that form the casing 106 even during the operations of separation of the shells 114 from the flange 112 and of separation of the separable portions 136 from the covers 124.
With reference to FIGS. 10 and 11, a fourth embodiment is shown in which the pod 100, substantially equal to the one of the first embodiment, also includes two radial patterns 138, present above and below the casing 106 of the pod 100, substantially equal to each other. The radial patterns 138 comprise a base 140 and a plurality of arch ribs 142. The base 140 has an axis, perpendicular to its surface, coinciding with the central axis A, and abuts against the surface of the casing 106 of the pod 100, and has a cross section that is smaller than the cross section of the inflow port 208 of the percolation chamber 202. The arch ribs 142 branch off from the base 140 following the upper and lower surface of the casing 106 of the pod 100, and connect at the internal perimeter of the respective upper ring 108 or lower ring 110.
The two radial patterns 138 are respectively formed integral with the upper ring 108 and the lower ring 110, preferably by means of a process of injection moulding or welding, thus surrounding the casing 106 of the pod 100.
In this embodiment, as in the first embodiment described above, the pod 100 must be inserted in packets that are hermetically vacuum sealed or contain an inert gas, such as gaseous nitrogen, so as to preserve the organoleptic characteristics of the coffee.
However, advantageously, the radial patterns 138, acting as spacers, prevent the sheets of filter paper 102 which form the casing 106 from coming into contact with the walls of the percolation chamber 202 and from clinging to said walls at the end of the beverage brewing process, thus avoiding any possible breaking of the casing 106 in the phase of removal of the pod 100.
Moreover, as in the first embodiment, the brewing process comes about by bringing the hot water under pressure substantially in contact with the sheets of filter paper 102 and the ground coffee. In fact, the water is in contact only in minimal part with portions of the radial patterns 138, whose ribs 142 are in a number barely sufficient to guarantee the support of the base 140 and the separation of the casing 106 from the walls of the percolation chamber 202. Thus, the organoleptic properties of the coffee are not altered and there are no undesirable substances released by the effect of the brewing process, thus guaranteeing a product of excellent quality.
A further objective of the invention is a method for producing the pod 100, in accordance with the four embodiments described above, which includes the steps outlined below:
Firstly, a portion of ground coffee is placed inside the casing 106, formed by two sheets of filtering elements 102 coupled to each other along their respective periphery 104.
Subsequently, the two sheets of filtering elements 102 are positioned above the lower ring 110 so that the axis of the casing 106 coincides with the axis of the lower ring 110 and with the central axis A of the pod 100, and also so that the periphery 104 is superimposed on and resting on the lower ring 110.
The upper ring 108 is then positioned so that the axis thereof coincides with axis of the lower ring 110, and also so that it rests on the upper surface of the periphery 104 of the sheets of filtering elements 102.
Subsequently, a pressure is applied on the upper and lower surface, respectively, of the upper ring 108 and of the lower ring 110, and these rings are joined to each other by a process of sealing union, preferably vibration welding, which induces the melting of the material of the lower surface and of the upper surface, respectively, of the upper ring 108 and of the lower ring 110.
In this step, therefore, the material is preferably melted by means of localized heating, generated in the vibration welding process by the friction in the contact region between the upper ring 108, the lower ring 110 and the periphery 104. In addition, a portion of the melted material embeds the sheets of filtering elements 102 that form the periphery 104.
Advantageously, this localized heating does not propagate inside the casing 106 of the pod 100, and thus the characteristics of the coffee contained therein remain unaltered.
Subsequently, the flange 112 is allowed to stabilize by cooling to a temperature adapted to maintain joined to each other the upper ring 108, the lower ring 110 and the periphery 104, so as to form a sealing flange 112 that seals and embeds the periphery 104 and that, moreover, is integral with the casing 106.
Finally, the pressure is released from the upper ring 108 and from the lower ring 110.
A further method of producing the pod 100 includes the following steps:
Firstly, the portion of ground coffee is placed inside the casing 106, formed by two sheets of filtering elements 102 coupled with each other along their respective periphery 104.
Subsequently, the two sheets of filtering elements 102 are positioned inside a cavity of a mould having a shape complementary to that of the pod 100. Specifically, said cavity includes a first cavity having a shape complementary to that of the casing 106 and a second injection cavity having a shape complementary to the sealing flange 112. The two sheets of filtering elements 102 are then inserted into the cavity of the mould in such a way that the casing 106 of the pod 100 is coaxial with the first cavity and in contact therewith and, moreover, the periphery 104 of the pod 100 is positioned inside the second injection cavity of the mould.
Subsequently, into the second injection cavity is injected a material, such as, preferably, PLA, so as to form the sealing flange 112 of the pod 100, which seals and embeds the periphery 104 and which, moreover, is integral with the casing 106 containing the coffee.
Next, the flange 112 is allowed to stabilize, by cooling, until it reaches a condition adapted to maintain the structural stiffness of the sealing flange 112.
Finally, the pod 100 is removed from the cavity of the mould.
From the above description it is evident that important results are achieved, by overcoming the drawbacks of the state of the art, making it possible to obtain a pod 100 having a structure that is suitable to guarantee, by means of the sealing flange 112, a hermetic closure of the percolation chamber 202 of the dispensing unit 200 such as to maintain the operating pressures of the espresso coffee machine, during the process of extracting the beverage.
The mechanical characteristics of the sealing flange 112 provide a structural stiffness to the pod 100 such as to allow an easy handling of the pod that can advantageously be performed in an automatic mode.
Moreover, the organoleptic characteristics of the beverage are not altered because the only elements of the pod 100 that are in contact with the water are, essentially, the sheets of filter paper 102, and the portion of the sealing flanges 112 or of the radial patterns 138 that remains in contact with the hot water under pressure is slight, compared with the surface area of the sheets of filter paper 102. Thanks to this reason, no undesirable substances are released into the extracted beverage and, therefore, the organoleptic properties of the coffee are not altered.
The use of materials of natural origin, such as filter paper 102 and the PLA of the sealing flange 112, the shells 114, the covers 124 and the radial patterns 138 reduces the environmental impact of the production of such pods.
Moreover, the materials used are biodegradable and compostable, and thus the disposal of the pod 100 at the end of its life is simplified, leading to a further decrease of the carbon footprint in the life-cycle of the coffee used for consumption through prepackaged, ready-to-use portions.
In addition, the pod 100 in the second and third embodiment is designed to use shells 114 or covers 124 that hermetically close the casing 106 inside a sealed chamber 122 or 132 that can contain an inert atmosphere, such as gaseous nitrogen or vacuum, making the prepackaged pod “self-protected”.
Thus, the second and the third embodiments, unlike the first and fourth embodiments, do not require a packaging, thus reducing the volume of the pod packages, with obvious logistical advantages in terms of storage and transportation.
In addition, the methods of production of the different portions of the pod 100 are simple and use plants, machines and equipment that are typical in the field.
While the present invention has been described with reference to various embodiments, including the preferred embodiments, it is clear that they are given by way of illustration, and that the invention is not limited to them alone.
Different variants, modifications, additions and improvements are possible and, for example, the shape of the annular sealing flange 112, which in the description and in the drawings of the invention is circular, can be formed in any suitable shape, such as for example elliptical, square, hexagonal, etc., provided it is complementary to the shape of the seat of the percolation chamber 202 of the dispensing unit 200 of the espresso coffee machine, adapted to receive said pod 100.
The pod 100, in the present invention, contains ground coffee, but it is possible to use the teaching of the present invention for the production of pods for the preparation of any beverage obtained from substances that can be extracted by forced percolation, such as for example tea or the like.
The methods of assembling the elements that form the pod 100, described in the present description include a joining and sealing process, such as vibration welding, but they can be substituted with other joining and sealing methods, the most suitable for the materials used, such as heat sealing, gluing with suitable bonding agent, or the like.
Naturally, in the present invention, the sealing flange 112, the shells 114, the covers 124 and the radial patterns 138 were made of PLA as thermoplastic material of natural origin that is biodegradable and compostable; however, it is clear that the material described is presented by way of example and that other thermoplastic polymers other than PLA can be used, such as for example biodegradable polymeric resins of natural origin (for example PHA, PHB, etc.) or of fossil origin (for example PBS, PVOH, etc.), combinations of these and/or combinations with fillers and/or reinforcements of organic and/or inorganic nature.
It is clear that, if it is not necessary that the pod 100 be biodegradable and compostable in its entirety, all and/or some of the portions that make up the pod 100 can be made of traditional thermoplastic polymers, such as for example PP, PET or the like, elastomers, thermosetting polymeric resins, or metals, such as for example aluminium, or the like.
Finally, the sealing flange 112, the shells 114, the covers 124 and the radial patterns 138 can be obtained by thermoforming from plates of poly-coupled multilayer materials made of metallic materials and/or polymers, the latter belonging, for example, to the categories described above.
Thus the materials, as well as the methods of production, the shapes and dimensions of the individual components forming the pod 100 of the present invention can be the most suitable to meet the specific requirements.

Claims

1-11. (canceled)

12. A pod for use in a hot beverage production machine, comprising:

two water-permeable filter elements mutually coupled along a periphery of said filter elements, said water-permeable filter elements being adapted to form a casing containing extractable substances by forced percolation; and

a sealing flange,

wherein said periphery of said filter elements is sealed and is embedded by said sealing flange, said sealing flange continuously extending around said casing.

13. The pod according to claim 1, wherein said sealing flange is adapted to provide structural stiffness to said pod to substantially prevent flexing of said water-permeable filter elements.

14. The pod according to claim 1, wherein said sealing flange comprises an upper ring and a lower ring joined together, said upper ring and lower ring having an inner radius equal to or greater than the radius of said casing and an outer radius greater than the radius of said periphery of said water-permeable filter elements, and said periphery being interposed between said upper ring and lower ring.

15. The pod according to claim 1, further comprising two shells joined, respectively, to said upper ring and to said lower ring, said two shells forming a chamber substantially hermetically enclosing said casing, and wherein said shells comprise, along a peripheral edge of each said two shells, a joint with, respectively, the upper ring and the lower ring, said joint being adapted to be separated by mechanical action exerted from the exterior of the pod.

16. The pod according to claim 1, further comprising two covers joined, respectively, to said upper ring and to said lower ring, said two covers forming a chamber hermetically enclosing said casing, and wherein said covers comprise a base having a separable portion adapted to be separated from said base by mechanical action exerted from the exterior of the pod.

17. The pod according to claim 4, wherein said chamber hermetically encloses said casing of the pod, said chamber further containing an inert atmosphere.

18. The pod according to claim 1, further comprising two radial patterns joined, respectively, to said upper ring and to said lower ring, said radial patterns surrounding said casing, said radial patterns comprising a base and a plurality of ribs, said ribs departing from the base, substantially following the upper and lower surfaces of the casing of the pod, said ribs being connected to at least one of the upper ring or the lower ring.

19. The pod according to claim 1, wherein at least one of said sealing flange, shells, covers or radial patterns is made of biodegradable materials.

20. A method for producing a pod comprising two water-permeable filter elements mutually coupled along a periphery of said filter elements, said water-permeable filter elements being adapted to form a casing containing extractable substances by forced percolation, the method comprising:

disposing said water-permeable filter elements over a lower ring so that the axis of the casing substantially coincides with the axis of the lower ring and with the central axis of the pod, said periphery being superimposed and resting on the lower ring;

disposing an upper ring so that the axis thereof substantially coincides with the axis of the lower ring and with the central axis of the pod, said upper ring resting on the upper surface of the periphery of the water-permeable filter elements;

applying a pressure on at least one of the upper surface of the upper ring or the lower surface of the lower ring;

joining together the upper ring and the lower ring so as to form a sealing flange sealing and embedding said periphery, said sealing flange continuously extending around said casing;

allowing the material of said sealing flange to substantially stabilize until it reaches a condition adapted to maintain joined together the upper ring, lower ring and periphery; and

removing the pressure from the at least one of the upper ring and the lower ring.

21. A method for producing a pod comprising two water-permeable filter elements mutually coupled along a periphery of said filter elements, said water-permeable filter elements being adapted to form a casing containing extractable substances by forced percolation, the method comprising:

disposing said water-permeable filter elements inside a mold cavity, said mold cavity comprising a first cavity having a shape complementary to said casing and a second injection cavity having a shape complementary to a sealing flange, so that the casing is substantially coaxial to the first cavity and the periphery is positioned into said second injection cavity;

injecting a material, into said second injection cavity, to form a sealing flange of the pod that seals and embeds said periphery, said sealing flange continuously extending around said casing;

allowing the material of said sealing flange to substantially stabilize until it reaches a condition adapted to maintain structural stiffness of the sealing flange; and

removing the pod from the mold cavity.