WO2016075316A1

WO2016075316A1 - A method of forming a cup-shaped body of a beverage capsule, a beverage capsule and a beverage preparation system

Info

Publication number: WO2016075316A1
Application number: PCT/EP2015/076617
Authority: WO
Inventors: Esak Shabudin
Original assignee: Koninklijke Douwe Egberts B.V.
Priority date: 2014-11-14
Filing date: 2015-11-13
Publication date: 2016-05-19
Also published as: GB201420263D0

Abstract

A method of forming a cup-shaped body of a beverage capsule, wherein a sheet of material comprises a laminate material comprising at least an aluminium layer and one or more polymer layers and, after formation, the one or more polymers layers are located towards an exterior of the cup- shaped body and the aluminium layer is provided towards an interior of the cup-shaped body. The cup-shaped body is formed by drawing the sheet of laminate material and, prior to being drawn, the one or more polymer layers of the laminate material have formed therein one or more apertures, slits and/or weakened areas. The one or more the apertures, slits and/or weakened areas are located on the sheet of material such that drawing of the cup-shaped body leads to at least a portion of a base of the cup-shaped body being provided with one or more basal apertures, basal slits and/or basal weakened areas in the one or more polymer layers of the base. An associated beverage capsule and system are also disclosed.

Description

A Method of Forming a Cup-Shaped Body of a Beverage Capsule, a Beverage Capsule and a Beverage Preparation System

The present disclosure relates to a method of forming a cup-shaped body of a beverage capsule, a beverage capsule and a beverage preparation system. The beverage preparation system is of the type comprising a beverage preparation machine wherein the capsule is designed for insertion into the beverage preparation machine to permit a pressurised liquid to be flowed through the capsule in order to produce a beverage from interaction with beverage ingredients contained within the capsule.

Background

Beverage preparation systems which comprise a beverage preparation machine and a beverage capsule containing beverage ingredients are known in the art. One such system is taught in EP1700548 and is shown in Figure 1. The system comprises a beverage capsule 100 having a thin aluminium cup-like body 104 and a closing foil member 102 and a beverage preparation machine having an enclosing member 2 and a capsule holder 20.

The enclosing member 2 comprises an annular element having a leading edge in the form of an annular rim 23. The leading edge may be provided with a plurality of grooves. An upper end of the enclosing member 2 may be coupled to a supply of water and also comprises one or more perforation elements 14 intended to pierce a base 117 of the capsule 100 in use. The one or more perforation elements 14 may take the form of needles or blades. The one or more perforation elements 14, as illustrated in Figure 1, are arranged along a circular path at a radius Rl from a central longitudinal axis of the enclosing member 2 so that in use the capsule 100 is intended to be perforated also at one or more points along a circular path at radius Rl from a central

longitudinal axis of the capsule 100 (which in use is substantially coincident with the central longitudinal axis of the enclosing member 2) .

The capsule holder 20 comprises relief elements 21 which are designed to tear and perforate the closing foil member 102 of the capsule 100. The tearing may occur due to internal pressurisation of the capsule 100 caused by

inflowing water. The relief elements 21 may have any

protruding shape able to cause a partial tearing of the foil member 102, e.g. pyramids, needles, bumps, cylinders, or elongated ribs.

The capsule 100 is suitable for insertion into the beverage preparation machine. During or after insertion the one or more perforation elements 14 form one or more

apertures in the aluminium base 117 of the capsule 100 to allow water under pressure to enter the capsule in order to interact with ingredients in the capsule to form a beverage which is output for consumption.

The capsule 100 of EP 1700548 is provided with a dedicated sealing member 108 to prevent a by-pass flow of water around the exterior of the capsule in use. The sealing member 108 is in the form of a resilient material attached to a flange of the capsule which is contacted on closure of the enclosing member 2 of the beverage preparation machine.

The present disclosure provides an alternative capsule which may be used as part of such a beverage preparation system. The capsule may be economical to produce and provide effective sealing in use. Summary of the Disclosure

In a first aspect the present disclosure provides a method of forming a cup-shaped body of a beverage capsule, the method comprising the step of forming from a sheet of material the cup-shaped body, the cup-shaped body comprising a base, a side wall and an open mouth opposite the base; wherein the sheet of material comprises a laminate material comprising at least an aluminium layer and one or more polymer layers and, after formation, the one or more polymers layers are located towards an exterior of the cup- shaped body and the aluminium layer is provided towards an interior of the cup-shaped body;

wherein the cup-shaped body is formed by drawing the sheet of laminate material;

wherein, prior to being drawn, the one or more polymer layers of the laminate material have formed therein one or more apertures, slits and/or weakened areas;

wherein the one or more the apertures, slits and/or weakened areas are located on the sheet of material such that drawing of the cup-shaped body leads to at least a portion of the base of the cup-shaped body being provided with one or more basal apertures, basal slits and/or basal weakened areas in the one or more polymer layers of the base .

In a second aspect the present disclosure provides a beverage capsule comprising a cup-shaped body formed using the method of the first aspect and a lid. In a third aspect the present disclosure provides a beverage producing system comprising:

a beverage capsule of the second aspect; and a beverage preparation machine;

the beverage capsule being designed for insertion into the beverage preparation machine to permit a pressurised liquid to be flowed through the capsule in order to produce a beverage from interaction with the beverage ingredients; the beverage preparation machine having an enclosing member adapted to be selectively 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 capsule.

In a fourth aspect the present disclosure provides a method of forming a beverage capsule containing one or more beverage ingredients, the method comprising the steps of: a) forming a cup-shaped body according to the method of the first aspect;

b) filling one or more beverage ingredients into the cup-shaped body through the open mouth; and

c) applying a lid to the cup-shaped body to close the open mouth.

The present disclosure provides a number of benefits. First, the use of a laminate material for forming the cup- shaped body allows an aluminium layer to be used towards an interior of the beverage capsule where it may be in contact with the one or more beverage ingredients and a polymer layer to be used towards an exterior of the beverage capsule for making an improved sealing contact with the beverage preparation machine.

A lacquer layer may be applied to the aluminium layer in between the aluminium layer and the one or more beverage ingredients. The aluminium layer may also form a barrier to ingress of oxygen and moisture into the beverage capsule in the case of a sealed beverage capsule.

Secondly, forming the cup-shaped body from a sheet of material which is a laminate material provides the advantage of providing the cup-shaped body with different materials for its inner- and outer-facing surfaces without the need to attach or cure in place a polymer material on an already- formed aluminium cup-shaped body.

The present applicant has found that, while the use of a laminate of aluminium and polymer material has the

advantages noted above, it can make piercing and use of the beverage capsule difficult. The presence of the one or more polymer layers can increase the initial resistance to piercing of the base of the beverage capsule. In addition, once pierced to form apertures in the base, the polymer material may have a tendency to cling on to the piercers of the beverage preparation machine which may inhibit entry of water into the beverage capsule through the apertures.

Consequently, the present method has the third benefit that the step of forming in the one or more polymer layers one or more apertures, slits and/or weakened areas prior to drawing that produce after drawing one or more basal apertures, basal slits and/or basal weakened areas advantageously produces a base of the capsule which may be more easily pierced by the piercing means of the beverage preparation machine. By at least partially removing the one or more polymer layers (preferably removing the polymer entirely) from the base where it will be contacted by the piercers the initial resistance to piercing may be reduced and the tendency for the polymer material to cling to the piercers may also be mitigated or avoided entirely. The above aspects may further comprise one or more of the following features, singly or in combination:

The one or more basal apertures, basal slits and/or basal weakened areas preferably extend across at least that portion of the base intended in use to be pierced by a perforation element of a beverage preparation machine.

The one or more basal apertures, basal slits and/or basal weakened areas may extend across an annular or

circular region of the base. This is particularly beneficial where the beverage capsule is rotationally symmetric and where the piercers of the beverage preparation machine are arranged on a circular path since it may be assured that the piercers will contact the basal apertures, basal slits and/or basal weakened areas irrespective of the rotational- orientation of the beverage capsule in the beverage

preparation machine.

The one or more basal apertures, basal slits and/or basal weakened areas may extend across a majority,

preferably a whole, of the base.

Drawing the cup-shaped body may stretch the one or more apertures, slits and/or weakened areas of the laminate material to form the one or more basal apertures, basal slits and/or basal weakened areas.

Preferably a deep drawing process may be used which may be a cold deep drawing process. Surprisingly, this has been found to be applicable to a sheet of material comprising a laminate of an aluminium layer and one or more polymer layers. As an alternative to cold-forming, a warm-drawing technique may be used where the material is subjected to an increased temperature to promote easier deformation of the polymer material (s) but without detrimental effects on the material characteristics of the aluminium layer.

The one or more apertures, slits and/or weakened areas may preferably be formed in the one or more polymer layers prior to laminating the one or more polymer layers to the aluminium layer.

Alternatively, the one or more apertures, slits and/or weakened areas may be formed in the one or more polymer layers after laminating the one or more polymer layers to the aluminium layer.

The one or more apertures, slits and/or weakened areas may be formed by cutting, pricking, slitting, ablating, chemically treating, lasering or melting the one or more polymer layers.

The sheet of material is preferably used to form multiple cup-shaped bodies. Consequently, the sheet of material may be provided with a repeating arrangement of apertures, slits and/or weakened areas - each unit of the repeating arrangement being destined for a different cup- shaped body after drawing. The units may be separated by intact portions of the one or more polymer layers.

Non-limiting examples of the apertures, slits and/or weakened areas include the following:

- a single aperture per cup-shaped body. The aperture may be 10-20mm in diameter, preferably 15mm in diameter;

- multiple pin-prick holes (each hole having a very small or zero opening prior to drawing) . The pin^¬ prick holes may be spaced by 2-3mm; and

- multiple slits (each slit having a very small or zero width prior to drawing) . The slits may have a length of 5-10mm. Where multiple apertures, slits and/or weakened areas are used per cup-shaped body these may be arranged in circumferential arrays, parallel line arrays, checkerboard arrays or a mixture thereof.

The aluminium layer may be formed from aluminium or an aluminium alloy. The aluminium alloy may, for example, be of grade 3005, 3105, 8011 or 8079. The aluminium alloy may have an 0' temper rating. The aluminium layer may have a thickness in the range of 80 to 150 microns, preferably 100 microns.

The one or more polymer layers may comprise a single layer of a single polymer material or multiple layers of different polymer materials. Where multiple layers of different polymer materials are used, each layer may be applied separately when making up the sheet of material. However, it is preferred that the multiple layers of

different polymer materials are first made up into a

multilayer laminated polymer film which can then be

laminated onto the aluminium layer by a suitable process, for example adhesive lamination.

The polymer materials of the one or more polymer layers may comprise materials selected from the group consisting of homopolymers , copolymers and mixtures thereof. By

homopolymer is meant a polymer produced by the

polymerization of a single monomer. By copolymer is meant a polymer produced by the polymerization of two or more monomers .

Suitable homopolymers include polyvinyl chloride (PVC) , polypropylene (PP) , low density polyethylene (LDPE) , medium density polyethylene (MDPE) , high density polyethylene

(HDPE) , polytetrafluoroethylene (PTFE) , polyethylene terephthalate (PET) , polychloroprene, polyisobutylene, and polyamides .

Suitable copolymers include fluorinated ethylene propylene (FEP) , ethylene propylene diene monomer (EPDM) , polyamides, thermoplastic copolyesters (TPC) and olefin block copolymers (OBC) . These copolymers are preferably alternating copolymers or block copolymers. By alternating copolymer is meant a copolymer with regular alternating monomer units. By block copolymer is meant a copolymer comprising two or more homopolymer subunits linked by covalent bonds .

The one or more polymer layers may also incorporate tie layers and/or one or more barrier layers for inhibiting transmission of moisture and/or oxygen. A suitable barrier layer material is ethylene vinyl alcohol (EVOH) .

In addition, optionally one or more lacquer layers or adhesive layers may be present in the sheet of laminated material. For example, an adhesive layer may be present between the aluminium layer and the one or more polymer layers. For example, an inner face of the aluminium layer may be coated with a lacquer layer, which may be for example of PVC.

The polymer materials preferably have a hardness of less than or equal to 40 D Shore Hardness, more preferably less than or equal to 30 D Shore Hardness. Advantageously, using relatively soft polymers for the outer surface of the cup-shaped body allows the material to deform around

imperfections and features of the enclosing member to provide a more effective hydraulic seal.

The one or more polymer layers may have a total thickness greater than or equal to 80 microns. A range of the total thickness of from 80 microns to 300 microns may be used. However, a total thickness of 100 microns for the one or more polymer layers has been found to be particularly effective .

In one example the sheet of material (before drawing) comprises an aluminium layer comprising aluminium alloy of grade 8011 with a thickness of 100 microns and a coextruded polymer film of 100 microns thickness giving a total thickness for the sheet of 200 microns. The coextruded polymer film in this example is Flextrus WB 100ET available from Flextrus Ltd of Highbridge, United Kingdom which is a multilayer coextruded film having a structure of PE - tie layer - EVOH - tie layer - PE .

Advantageously, combining a relatively soft polymer (s) of less than or equal to 30 D Shore Hardness with a total thickness of 100 microns beneficially results in a material that can deform sufficiently to seal around moderately sized imperfections and features of the enclosing member without requiring too high a closing force on the enclosing member to operate.

The beverage capsule may further contain one or more beverage ingredients.

The cup-shaped body may comprise an outwardly-extending flange at an end of the beverage capsule distal the base.

The outwardly-extending flange may be formed from the sheet of laminate material.

The cup-shaped body may be wholly formed from the sheet of laminate material.

The cup-shaped body may comprise a unitary piece of laminate material.

The cup-shaped body may be adapted to form a sealing interface with a leading edge of the enclosing member. Advantageously, the deformation of the cup-shaped body due to the compressibility of the one or more polymer layers allows for the beverage capsule to conform to the shape of the leading edge of the enclosing member. In particular the one or more polymer layers are able to fill any gaps arising due to the presence of grooves in the leading edge.

The laminate material of the beverage capsule may be adapted to be nipped against a capsule holder of the

beverage preparation machine part.

The beverage capsule may further comprise a rim. The rim may be integral with the cup-shaped body. The rim may be formed by a rolled-over portion of the side wall.

The side wall may comprise a frustoconical section.

The lid may be sealed to an outwardly-extending flange of the cup-shaped body.

The lid may be formed from aluminium, an aluminium alloy or a laminate comprising at least one layer formed from aluminium or an aluminium alloy. Alternatively, another, suitably ductile material could be utilised. The lid may further comprise a heat seal lacquer or heat seal layer to enhance sealing of the lid to the cup-shaped body.

The rim may have an outer diameter of approximately 37 mm.

Prior to insertion, the beverage capsule may have a height of from 25 to 31 mm. In some aspects the height may be from 28.5 to 30 mm.

Preferably, the cup-shaped bodies may be shaped in a way that can be stacked and destacked easily prior to filling and assembly with the lids.

The beverage capsule may form a single-use, disposable element . The beverage capsule may contain a beverage ingredient or mixture of beverage ingredients. As a non-limiting example, the beverage ingredient may comprise roasted ground coffee .

The beverage preparation machine of the beverage preparation system may comprise one or more piercers which pierce a portion of the base of the beverage capsule covered in the one or more basal apertures, basal slits and/or basal weakened areas when the enclosing member is moved into the closed position.

Brief Description of the Drawings

Examples of the present disclosure will now be

described in more detail, for exemplary purposes only, with reference to the accompanying drawings, in which:

Figure 1 is a cross-sectional view of a prior art beverage preparation system as disclosed in EP1700548;

Figure 2 is a cross-sectional schematic view of a first example of capsule according to the present disclosure;

Figure 3 is a schematic illustration of a detail of the capsule of Figure 2 with an enclosing member of a beverage preparation machine in a closed position;

Figure 4 is a schematic cross-section of a laminate material for the capsule of Figure 2;

Figure 5 is a schematic cross-section of another laminate material for the capsule of Figure 2;

Figure 6 is a schematic view of a first example of a sheet of material for use in the method of the present disclosure ; Figure 7 is a schematic view of a second example of a sheet of material for use in the method of the present disclosure ;

Figure 8 is a schematic view of three examples of arrangements of apertures, slits and/or weakened areas that can be used for the sheet of material of Figure 7; and

Figure 9 is a schematic illustration of a method of laying up a sheet of material of the present disclosure. Detailed Description

Figure 2 illustrates an example of a beverage capsule 1 according to the present disclosure which may be used with a beverage preparation machine to produce a beverage. The beverage capsule 1 and the beverage preparation machine together define a beverage preparation system.

The beverage capsules of the present disclosure may be used, for example, with a beverage preparation machine of the general type shown in Figure 1, described in brief above and in more detail in EP1700548. However, they may also be used in other beverage preparation machines and, in the following description, reference to features of a beverage preparation machine of the general type described in

EP1700548 is by way of example only.

The enclosing member 2 and the capsule holder 20 in the closed position together define a receptacle 30 for holding the beverage capsule 1 during a dispensing operation. The enclosing member 2 may be moved between the open and closed positions by means of a conventional mechanism well known in the art. For example, the means may involve a mechanical mechanism activated by a manually-movable lever or an automatic or semi-automatic mechanism where movement is driven by a motor. The enclosing member 2 may be moved while the capsule holder 20 remains stationary. Alternatively, the enclosing member 2 may remain stationary and the capsule holder 20 be moved. In a further alternative arrangement, both the enclosing member 2 and the capsule holder 20 may move during the opening and closing operations.

In addition, the beverage preparation machine may comprise conventional elements which are not illustrated in the accompanying drawings and which are well known in the art of beverage preparation machines. For example, the beverage preparation machine may comprise either a facility for storing water, such as an internal reservoir, or a facility for connection to an external supply of water, such as mains water. A pump or equivalent may be provided for supplying the water in a pressurised state to the beverage capsule 1. The water will typically be supplied at a

pressure of up to 9 to 14 bar. A heater may be provided for heating the water to a desired temperature. The heater may heat the water in the reservoir (where present) or may heat the water on-demand as it passes through a conduit or over a thermoblock to the receptacle 30.

The beverage capsule 1 of Figure 2 may have the general form of a cup-shaped body 40 having a base 42 at one end and a side wall 43 extending from the base 42 towards an opposed end, which is open to form a mouth of the cup-shaped body 40 which is closed-off by a lid 41 after filling with one or more beverage ingredients.

As shown in Figure 2, the cup-shaped body 40 and the lid 41 of the beverage capsule 1 together enclose a beverage ingredient chamber 50 which may be filled with a beverage ingredient or mixture of beverage ingredients. As a non- limiting example, the beverage ingredient may comprise roasted ground coffee. The cup-shaped body 40 is formed from a sheet of material (which will be described in more detail below) in the form of a laminate material comprising at least an aluminium layer 71 and a polymer layer 72. Multiple polymer layers may be present but in the example of Figure 2 only one polymer layer 72 is shown for simplicity.

The laminate material may, optionally, have one or more tie layers and/or adhesive layers as necessary to bond together the layers 71 and 72. Preferably the adhesive layer is formed from a food-grade adhesive. Additionally, the laminate material may comprise one or more lacquer layers on its inner and/or outer surface.

The general structure of the sheet of laminate material is shown in Figure 4 - the tie and/or adhesive and/or lacquer layers are omitted from the drawing for clarity. Again, as with Figure 2, multiple polymer layers may be present but only one polymer layer 72 is shown in Figure 4 for simplicity.

The polymer materials of the one or more polymer layers 72 may comprise materials selected from the group consisting of homopolymers , copolymers and mixtures thereof. By

homopolymer is meant a polymer produced by the

polymerization of a single monomer. By copolymer is meant a polymer produced by the polymerization of two or more monomers.

(HDPE) , polytetrafluoroethylene (PTFE) , polyethylene

terephthalate (PET) , polychloroprene, polyisobutylene, and polyamides . Suitable copolymers include fluorinated ethylene propylene (FEP) , ethylene propylene diene monomer (EPDM) , polyamides, thermoplastic copolyesters (TPC) and olefin block copolymers (OBC) . These copolymers are preferably alternating copolymers or block copolymers. By alternating copolymer is meant a copolymer with regular alternating monomer units. By block copolymer is meant a copolymer comprising two or more homopolymer subunits linked by covalent bonds .

The sheet of laminate material may also incorporate tie layers and/or one or more barrier layers for inhibiting transmission of moisture and/or oxygen. A suitable barrier layer material is ethylene vinyl alcohol (EVOH) .

The polymer materials used preferably have a hardness of less than or equal to 30 D Shore Hardness.

The polymer layer 72 (or multiple polymer layers where present) may have a total thickness t_p greater than or equal to 80 microns. A range of the total thickness t_p of from 80 microns to 300 microns may be used. In one example, a total thickness t_p of 100 microns is used.

The aluminium layer 71 may have a thickness t_a in the range of 80 to 150 microns. In one example, a thickness t_a of 100 microns is used.

The polymer layer 72 is provided towards an exterior of the beverage capsule 1 to be contacted by the enclosing member 2 and the aluminium layer 71 is provided towards an interior of the beverage capsule 1.

A lacquer layer may be provided which may be applied to the aluminium layer 71. The lacquer layer may be PVC .

The laminate material may also comprise a printed layer facing the exterior of the beverage capsule 1, to allow the provision of text, pictures, logos, etc. The polymer layer 72 provides a compressible structure that aids sealing.

In another example, shown schematically in Figure 5, a suitable laminate material for the sheet of material for forming the cup-shaped body 40 comprises an aluminium layer 71 comprising aluminium alloy of grade 8011 with a thickness t_a of 100 microns and a coextruded polymer film 74 with a thickness t_p of 100 microns giving a total thickness for the sheet of material prior to forming into the cup-shaped body 40 of 200 microns. The coextruded polymer film may, for example, comprise a layer of polyurethane and a layer of polyethylene. In another example, the coextruded polymer film 74 may be Flextrus WB 100ET available from Flextrus Ltd of Highbridge, United Kingdom which is a multilayer

coextruded film having a structure of an upper PE layer 74a, a tie layer 74b, an EVOH layer 74c, a tie layer 74d and a PE layer 74e.

Other suitable materials for laminating with the aluminium layer 71 include:

· Flextrus WB 200ET (also available from Flextrus Ltd) which differs from Flextrus WB 100ET in that the coextruded film is 200 microns thick;

• Queo 0210 Octene-1 Plastomer available from Borealis Group, Vienna, Austria;

· Infuse 9107 olefin block copolymer available from The

Dow Chemical Company of Midland, Michigan, USA;

• Arnitel thermoplastic copolyetheresters available from DSM of Birmingham, MI, USA.

The cup-shaped body 40 includes the base 42 and the side wall 43. There may be, as illustrated, a geometric discontinuity at the junction between the base 42 and the side wall 43, for example, in the form of a shoulder 57. Alternatively, the base 42 and the side wall 43 may have a smooth geometric transition.

The side wall 43 of the cup-shaped body 40 may

comprise, as shown, an outwardly-extending flange 70 at an end of the beverage capsule 1 distal the base 42. In which case, preferably the whole of the outwardly-extending flange

70 is made from the sheet of laminate material. The flange

70 may be provided with a rim 47 which may be formed by a rolled-over section of the flange.

Preferably the whole of the cup-shaped body 40 is made from the sheet of laminate material, including the flange 70 and rim 47 where present. Also, preferably, the cup-shaped body 40 is formed from a unitary piece of the sheet of laminate material.

The cup-shaped body 40 may be formed by cold drawing the laminate material. Preferably a deep drawing process is used .

The lid 41 may be sealed to an underside of the

outwardly-extending flange 70. Alternatively, the lid 41 could be sealed to the side wall 43 at a location spaced from the outwardly-extending flange 70 of the cup-shaped body 40.

The lid 41 may be formed from aluminium or a laminate containing aluminium.

According to the present disclosure, the one or more polymer layers 72 of the sheet of material from which the cup-shaped body 40 is formed is provided with one or more apertures, slits and/or weakened areas.

Figure 6 illustrates a first example wherein the sheet of material 110 comprises a plurality of apertures 120 in the one or more polymer layers 72 that expose the underlying aluminium layer 71. In this example each aperture 120 is a single, round hole 121 and the sheet is destined to be drawn into fifteen cup-shaped bodies 40 such that each cup-shaped body 40 will have a single basal aperture. Each aperture 120 may have a diameter of 15mm. When drawn in a deep drawing process, the round hole 121 will be stretched and enlarged to as to form a basal aperture of generally round shape in the polymer material which will cover a majority of (or the entire) of the base 42 of the cup-shaped body 40.

Consequently, the base 42 (or at least that portion of the base which will be contacted by the perforation elements 14) will comprise only the aluminium layer 71.

Figure 7 illustrates a second example wherein the sheet of material 110 comprises a regular array of patterned slits

122 in the one or more polymer layers 72. In this example the patterned slits 122 comprise a repeating pattern of a see-saw slit line 123 (shown in more detail in the right- hand part of Figure 8) . As in Figure 6, the sheet of

material 110 is destined to be drawn into fifteen cup-shaped bodies 40. In this example, each cup-shaped body 40 will have a plurality of basal slits. Prior to drawing each see^¬ saw slit line 123 may have a zero width (i.e. not exposing the underlying aluminium layer 71) and a length of 5-10mm. When drawn in a deep drawing process, the see-saw slit lines

123 will be stretched and enlarged to as to form a plurality of basal slits that will have a non-zero width thereby exposing the underlying aluminium layer 71. The basal slits may cover a majority of (or the entire) of the base 42 of the cup-shaped body 40. Consequently, the base 42 (or at least that portion of the base which will be contacted by the perforation elements 14) will comprise exposed portions of the aluminium layer 71. Two further examples of patterned slits 122 are shown in the left-hand and middle portions of Figure 8. To the left is shown a circumferential array of radial slits 125. In the middle is shown a parallel arrangement of straight slits 124. As above, prior to drawing the slits 124, 125 may have a zero width but on drawing are stretched to expose the underlying aluminium layer 71.

The apertures and/or slits may be formed in the one or more polymer layers 72 by use of suitable means such as cutters , punches, needles, stamps, etc. In addition the apertures, slits and/or weakened areas may be formed by lasering the one or more polymer layers 72.

Figure 9 illustrates a suitable apparatus for laying up the sheet of material 110. An aluminium reel 130 contains a web 137 of aluminium destined to form the aluminium layer 71. A polymer reel 132 contains a web 138 of polymer

material destined to form the one or more polymer layers 72. The polymer material as discussed above may be a single layer of a single material or may be a multilayer material, for example a coextruded film. In this example the polymer material has already had formed therein the apertures, slits and/or weakened areas.

In laying up the web 138 of polymer material is fed through an adhesive deck 133 which applies an adhesive layer to the web. The polymer-adhesive web 139 is then fed through an oven 134 to soften the adhesive layer and also to

beneficially anneal the polymer material. Next the polymer- adhesive web 139 is fed to a pair of nip rollers 135 where it is adhered to the aluminium web 137 taken off the

aluminium reel 130. The laid-up web 140 is then fed over a chill roller 136 to cool the web before being wound onto a storage reel 131. The deep drawing of the sheet of material 110 into the cup-shaped bodies 40 can then be carried out.

In use of the beverage preparation system the enclosing member 2 is first moved into the open position and the beverage capsule 1 is inserted into a location in between the capsule holder 20 and the enclosing member 2. Depending on the design of the beverage preparation machine, the beverage capsule 1 may be inserted by gravity or by manual placement or a combination thereof. In addition, the initial insertion may place the beverage capsule 1 in proximity to the enclosing member 2 such that subsequent movement of the enclosing member 2 carries the beverage capsule 1 therewith into engagement with the capsule holder 20. Alternatively, initial insertion may place the beverage capsule 1 in proximity to the capsule holder 20 such that the beverage capsule 1 remains substantially stationary during closure of the enclosing member 2.

The enclosing member 2 is then closed so as to

sealingly engage the enclosing member 2 with the beverage capsule 1. During this step the base 42 of the beverage capsule 1 is pierced by the perforation elements 14 of the enclosing member 2 through the area of the base covered by the basal apertures, basal slits and/or basal weakened areas .

Pressurised aqueous medium is then flowed into the beverage capsule 1 to produce a beverage from interaction with the beverage ingredients. During this step internal pressurisation of the beverage ingredient chamber 50 causes the lid 41 to be deformed outwardly against the relief elements 21 of the capsule holder 20 resulting in at least partial tearing of the lid 41 which opens up an exit path from the beverage capsule 1 for the beverage. The beverage is then output for consumption.

As shown in Figure 3, during the step of closing the enclosing member 2 relative to the capsule holder 20 the flange 70 (or other part of the side wall 43) of the

beverage capsule 1 is contacted by the enclosing member 2 to deform the flange 70 (or other part of the side wall 43) . In the example shown, the enclosing member 2 contacts the flange 70 only. However, other arrangements are contemplated by the present disclosure whereby the enclosing member 2 contacts a different portion of the side wall 43, e.g. a frustoconical portion, or contacts multiple locations of the beverage capsule 1.

The leading edge 23 contacts and bears on the laminate material of the side wall 43 and nips the laminate material against the capsule holder 20. The enclosing member 2 thereby deforms at least the one or more polymer layers 72 of the laminate material forming a sealing interface between the enclosing member 2 and the beverage capsule 1. The deformation of the laminate material due to the

compressibility of the one or more polymer layers 72 allows for the laminate material to conform to the shape of the leading edge 23. In particular the one or more polymer layers 72 are able to fill any gaps arising due to the presence of grooves in the leading edge 23. In addition, during use the hot water passed through the receptacle 30 may act to slightly soften the material of the polymer layer (s) 72. Such softening may lead to further deformation of the side wall 43 under the compressive loading of the enclosing member 2. This effect may help to reinforce the fluid seal between the enclosing member 2 and the beverage capsule 1 by tending to seal up any gaps having hot water leaking there through. The deformation of the one or more polymer layers 72 may be elastic, plastic or a combination of the two.

Claims

Claims :

1. A method of forming a cup-shaped body of a beverage capsule, the method comprising the step of forming from a sheet of material the cup-shaped body, the cup-shaped body comprising a base, a side wall and an open mouth opposite the base;

wherein the sheet of material comprises a laminate material comprising at least an aluminium layer and one or more polymer layers and, after formation, the one or more polymers layers are located towards an exterior of the cup- shaped body and the aluminium layer is provided towards an interior of the cup-shaped body;

wherein the one or more the apertures, slits and/or weakened areas are located on the sheet of material such that drawing of the cup-shaped body leads to at least a portion of the base of the cup-shaped body being provided with one or more basal apertures, basal slits and/or basal weakened areas in the one or more polymer layers of the base.

2. The method of claim 1, wherein the one or more basal apertures, basal slits and/or basal weakened areas extend across at least that portion of the base intended in use to be pierced by a perforation element of a beverage

preparation machine.

3. The method of claim 1 or claim 2, wherein the one or more basal apertures, basal slits and/or basal weakened areas extend across a majority, preferably a whole, of the base .

4. The method of any preceding claim, wherein drawing the cup-shaped body stretches the one or more apertures, slits and/or weakened areas of the laminate material to form the one or more basal apertures, basal slits and/or basal weakened areas.

5. The method of any preceding claim, wherein the one or more apertures, slits and/or weakened areas are formed in the one or more polymer layers prior to laminating the one or more polymer layers to the aluminium layer.

6. The method of any of claims 1 to 4, wherein the one or more apertures, slits and/or weakened areas are formed in the one or more polymer layers after laminating the one or more polymer layers to the aluminium layer.

7. The method of any preceding claim, wherein the one or more apertures, slits and/or weakened areas are formed by cutting, pricking, slitting, ablating, chemically treating, lasering or melting the one or more polymer layers.

8. A beverage capsule comprising a cup-shaped body formed using the method of any preceding claim and a lid.

9. A beverage producing system comprising:

a beverage capsule as claimed in claim 8; and

a beverage preparation machine; the beverage capsule being designed for insertion into the beverage preparation machine to permit a pressurised liquid to be flowed through the capsule in order to produce a beverage from interaction with the beverage ingredients; the beverage preparation machine having an enclosing member adapted to be selectively movable between an open position to permit insertion of the capsule into the

10. The beverage producing system of claim 9, wherein the beverage preparation machine comprises one or more piercers which pierce a portion of the base of the beverage capsule covered in the one or more basal apertures, basal slits and/or basal weakened areas when the enclosing member is moved into the closed position.

11. A method of forming a beverage capsule containing one or more beverage ingredients, the method comprising the steps of:

a) forming a cup-shaped body according to the method of any of claims 1 to 7;

c) applying a lid to the cup-shaped body to close the open mouth.