WO2016075318A1

WO2016075318A1 - A method of forming a beverage capsule, a beverage capsule and a beverage preparation system

Info

Publication number: WO2016075318A1
Application number: PCT/EP2015/076619
Authority: WO
Inventors: Andrew Halliday; Esak Shabudin; Glen OLIVER; Nicholas Hansen
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: GB201420259D0

Abstract

A method of forming a beverage capsule containing one or more beverage ingredients, the method comprising the steps of: a) forming from a sheet of material a cup-shaped body, the cup-shaped body comprising a base, a side wall and an open mouth opposite the base; 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; 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 beverage capsule and the aluminium layer is provided towards an interior of the beverage capsule. At least a first portion of the base is made thinner than a second portion of the base and the first portion of the base is made thinner by displacing or removing at least a portion of the one or more polymer layers. An associated beverage capsule and system are also disclosed.

Description

A Method of Forming a Beverage Capsule, a Beverage Capsule and a Beverage Preparation System

The present disclosure relates to a method of forming 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 (also known as piercers) 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 beverage capsule containing one or more beverage ingredients, the method comprising the steps of: a) forming from a sheet of material a cup-shaped body, the cup-shaped body comprising a base, a side wall and an open mouth opposite the base;

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;

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 polymer layers are located towards an exterior of the beverage capsule and the aluminium layer is provided towards an interior of the beverage capsule;

wherein at least a first portion of the base is made thinner than a second portion of the base; and

wherein the first portion of the base is made thinner by displacing or removing at least a portion of the one or more polymer layers. In a second aspect the present disclosure provides a beverage capsule comprising a cup-shaped body and a lid; the cup-shaped body having a base, a side wall and an open mouth opposite the base; the lid being sealed to the cup-shaped body to close the open mouth;

wherein the cup-shaped body is formed from a sheet of laminate material comprising at least an aluminium layer and one or more polymer layers with the one or more polymers layers being located towards an exterior of the beverage capsule and the aluminium layer being provided towards an interior of the beverage capsule;

wherein at least a first portion of the base is thinned relative to a second portion of the base such that the thickness of the one or more polymers layers in the first portion is less than in the second portion.

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.

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 a 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 thinning the first portion of the base by displacing or removing at least a portion of the one or more polymer layers advantageously produces a base of the capsule which may be more easily pierced by the piercing means of the beverage preparation machine. By reducing the thickness of the one or more polymer layers (or removing the polymer entirely) from the first portion of the base the initial resistance to piercing may be reduced and the tendency for the polymer material to cling to the piercers may also be mitigated. Consequently, the first portion of the base may be regarded as a weakened zone of the base. The above aspects may further comprise one or more of the following features, singly or in combination:

The total thickness of the one or more polymer layers may be reduced by 40% or greater, more preferably by 60% or greater during the thinning step.

The first portion may be made thinner by displacing or removing at least a portion of the one or more polymer layers during or after step a) . For example, the first portion may be made thinner as part of the manufacturing steps which form the cup-shaped body or may, alternatively be made thinner as a separate processing step applied to the cup-shaped body after it has been formed.

The first portion of the base is preferably intended to be pierced in use of the beverage capsule by a beverage preparation machine in which the beverage capsule can be inserted. Preferably the size and location of the first portion of the base may be configured to ensure that when pierced by an associated beverage preparation machine the piercers of the beverage preparation machine contact only the thinned section of the first portion and do not contact a remainder of the base and, preferably, also do not contact at an interface between the first portion and the remainder of the base. In this way better piercing of the base may be promoted by ensuring that the piercers contact only the weakened zone of the first portion of the base.

The first portion may comprise 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 first portion of the base irrespective of the rotational-orientation of the beverage capsule in the beverage preparation machine.

The displacement of at least a portion of the one or more polymer layers from the first portion of the base may form one or more raised ribs, wherein the raised ribs have a thickness greater than the second portion of the base. The formation of the raised rib(s) may create a localised stiffening of the base at the interface (s) between the first portion and the second portion of the base. This may promote piercing of the first portion during use as the raised rib(s) help to prevent large-scale deformation of the whole base away from the approaching piercers during the

perforation action.

The one or more raised ribs may be formed at an inner and/or outer interface between the first portion and the second portion of the base.

The one or more raised ribs may be formed on an outer and/or an inner face of the base.

The one or more raised ribs may have a thickness of greater than 200 microns, preferably greater than 300 microns .

The sheet of material prior to step a) may have a uniform thickness. Using a sheet of uniform thickness at the start of the formation process increases the ease and uniformity of the shaping of the cup-shaped body, in

particular where deep drawing is utilised. Thus it has been found to be preferred to start with a sheet of material of uniform thickness and then thin a section of the base of the beverage capsule during or after formation of the cup-shaped body.

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, 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. A lacquer coating of 10 microns thickness may be provided on an inner face of the aluminium layer. Thus, the total thickness for the example sheet is approximately 210 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.

In step a) the cup-shaped body may be formed by deep drawing the sheet of material. The deep drawing process 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.

There are a number of possible options for thinning the first portion of the base. In a first option the first portion of the base is made thinner by displacing or removing at least a portion of the one or more polymer layers by applying a heated tool to the base. Preferably, the heated tool is used after the cup-shaped body is formed in step a) and before the beverage ingredients are filled in step b) . The heated tool may have a temperature of 250 to 300°C. In one example the temperature is 280 °C.

The heated tool may be applied to the base with a force of 500 to 1000N.

The heated tool may be applied to the base for 0.1 to

0.6 seconds, preferably 0.3 seconds.

The use of the heated tool can be used to form the one or more raised ribs described above as the heat from the tool may cause the one or more polymer layers to soften and/or melt and be displaced sideways away from the first portion of the base. This effect may be beneficially

increased by applying the heated tool to the base with the force of 500 to 1000N noted above. The material so displaced cools and solidifies/hardens at the edges of the first portion at the interface with the second portion to form the raised ribs. The first portion may form a weakened zone of the base and the raised ribs may form a stiffening element of the base.

In a second option the first portion of the base is made thinner by displacing or removing at least a portion of the one or more polymer layers by use of a laser. The laser may be used to ablate at least a portion of the one or more polymer layers. The laser beam may be moved and the cup- shaped body held stationary during ablation. Alternatively, and preferably where the first portion forms an annular shape, the laser beam may be fixed and the cup-shaped body rotated relative to the laser beam. Preferably, the laser may be used on the cup-shaped body after step a) and before filling the one or more beverage ingredients in step b) . Alternatively, the laser may be used on the cup-shaped body after the beverage capsule has been lidded in step c) . A narrow or wide laser beam may be used. An example of a suitable apparatus is the Firestar F-series of C0₂ lasers, available from Synrad, Inc. of Mukilteo, WA, USA. The output power may be of the order of 40W and the power may be modulated. A flat field lens may be used. The laser

wavelength may be 10.6 microns and the frequency 20kHz. A beam duration time of the order of 3 seconds may be used and the beam may be steered during energisation to mark out the first portion.

The use of the laser can be used to form the one or more raised ribs described above as the heat from the laser beam may cause some of the one or more polymer layers to soften and/or melt and be displaced sideways away from the first portion of the base (possibly together with ablation of other material) . The material so displaced cools and solidifies/hardens at the edges of the first portion at the interface with the second portion to form the raised ribs. The first portion may form a weakened zone of the base and the raised ribs may form a stiffening element of the base.

In a third option the first portion of the base is made thinner by displacing at least a portion of the one or more polymer layers by mechanically squashing the first portion of the base during or after step a) .

Preferably the first portion of the base is subjected to a higher level of force during the mechanical squashing than the second portion of the base.

In a first example of this third option, a raised formation may be created at the location of the first portion of the base in a first step and, in a second step, the raised formation may be squashed so as to thin the first portion of the base by displacing at least some of the one or more polymer layers. By first forming a raised formation before applying a squashing force the forces may be

concentrated on the area of the first portion of the base resulting in better displacement of the one or more polymer layers .

The raised formation may be formed by the shaping of the tools used for drawing the sheet of material. For example, a set of drawing tools may be provided comprising a first upper tool and a bottom tool for the first step of the drawing process and a second upper tool for the second step of the drawing process. The bottom tool may be shaped to configure an inner surface of the cup-shaped body and may comprise a raised step. The first upper tool may be shaped to configure an outer surface of the cup-shaped body and may comprise a cavity. The raised step of the bottom tool and the cavity of the first upper tool together act to form the raised formation of the cup-shaped body as the first upper tool and bottom tool are brought together at the end of the first step of the drawing process at which point the cup- shaped body is in an intermediate form. Alternatively, the cup-shaped body may be deep drawn by a prior operation and the first upper tool and the bottom tool be used

subsequently just to form the raised formation.

The first upper tool is then swapped out in the drawing rig for the second upper tool. The second upper tool has no cavity at the location of the first portion of the cup- shaped body but rather has a continuous surface level. The second upper tool and the bottom tool are then compressed together with the intermediate form of the cup-shaped body therebetween. Consequently, the raised step of the bottom tool and the surface of the second upper tool squeeze between them the first portion of the base causing

displacement of at least a portion of the one or more polymer layers. The pressure of the tools may also produce some thinning of the aluminium layer in addition to the thinning of the one or more polymer layers.

The raised formation formed in the base may be a raised step. The raised step may have two riser segments extending upwardly from a remainder of the base and a tread segment spanning between the riser segments so that the raised step has a generally shallow N-shaped profile in cross-section. Alternatively, the raised formation may be a raised rib, ridge or similar.

The raised formation preferably has a height of 0.18 to 0.35mm, more preferably 0.25mm.

In a second example of this third option, mechanically squashing the first portion of the base forms at least one raised rib. The at least one raised rib may be formed at an inner and/or outer interface between the first portion and the second portion of the base. In one example two raised ribs are formed, one to each side of the first portion so as to border the first portion and demarcate an interface between the thinner material of the first portion and the thicker material of the second portion. The raised ribs themselves are preferably significantly thicker than the second portion of the base too. The first portion may form a weakened zone of the base and the raised ribs may form a stiffening element of the base.

The at least one raised rib is preferably formed on an inner face of the base. In this way, the outer face of the base may be kept substantially smooth and free of raised formations. This may allow for an improved aesthetic

appearance of the beverage capsule and better fitment of the beverage capsule within the capsule holder of the beverage preparation machine. The mechanical squashing may also thin the aluminium layer within the first portion. However, the majority of the thinning of the first portion may typically be due to displacement of the one or more polymer layers. For example, in the case of a laminate formed of a 100 micron aluminium layer and 100 microns of polymer (in one or more layers) the thickness of the first portion after mechanical squashing may be, for example, 100 microns, comprised of a 10 micron thickness of polymer and a 90 micron thickness of aluminium.

The base may be mechanically squashed between an upper tool and a bottom tool, and the bottom tool may comprise at least one recess for forming the at least one raised rib. The at least one recess accommodates the displaced material from the first portion and shapes and confines the displaced material to form the at least one raised rib. Preferably one recess per raised rib is provided. Each recess may be a circumferential recess in the bottom tool. Where two or more circumferential recesses are provided they may be arranged concentrically.

The at least one recess may extend to a point 80 to

120, preferably 100 microns below a datum surface level of the bottom tool.

The bottom tool may comprise a raised step in between the recesses. The raised level of the raised step may be used to determine the ultimate thickness of the material in the first portion.

The raised step may extend 100 to 140, preferably 120 microns above the datum surface level of the bottom tool.

The contact face of the upper tool may be flat in the region of the first portion, i.e. smooth, so as to form the outer face of the base free of raised formations in the region of the first portion. The cup-shaped body may be first deep drawn using separate tooling and then transferred onto the bottom tool for mechanical squashing. Alternatively, the mechanical squashing may take place at the same time and with the same tooling used to deep draw the cup-shaped body.

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

The beverage preparation machine may comprise one or more piercers which pierce the first portion of the base of the beverage capsule when the enclosing member is moved into the closed position. Preferably the piercers will only contact the thinned material of the first portion of the base .

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 outwardly-extending flange may comprise at least one raised ridge formed from the sheet of laminate material. The at least one raised ridge may be on the side of the outwardly-extending flange that faces away from the lid.

On closure of the enclosing member a leading edge of the enclosing member may contact the at least one raised ridge and form a seal therewith.

The raised ridge may comprise an apex that is located at a higher level relative to a remainder of the flange.

The raised ridge may comprise an inner wall facing the side wall. On closure of the enclosing member a leading edge of the enclosing member may contact the inner wall of the raised ridge and forms a seal therewith.

The inner wall of the raised ridge may be angled, such that an angle a at a junction between a remainder of the flange and the inner wall is from 90° to 120°, preferably 105°. Thus the seal with the enclosing member may be a tapered seal.

The raised ridge may comprise an apex, and a leading edge of the enclosing member may comprise an inner rim and an outer rim and a recess located between the inner rim and the outer rim, wherein on closure of the enclosing member the apex of the raised ridge may be received in the recess between the inner rim and the outer rim.

The raised ridge may have a height of 0.75 to 2.5 mm, preferably 1.0 to 1.5 mm, more preferably 1.3 mm.

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 sealed to the side wall at a location spaced from 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 .

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 an enlarged view of a portion of Figure 2;

Figure 4 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 5 is a schematic cross-section of a laminate material for the capsule of Figure 2;

Figure 6 is a schematic cross-section of another laminate material for the capsule of Figure 2;

Figure 7 is a schematic cross-sectional view of an apparatus for applying a heated tool to a base of a cup- shaped body;

Figure 8 is a cross-sectional view of the heated tool of Figure 7;

Figure 9 is a picture of the base of a cup-shaped body after use of the apparatus of Figure 7;

Figure 10 is a cross-sectional view of a portion of the base of a cup-shaped body after use of the apparatus of Figure 7;

Figure 11 is a view of a base of a cup-shaped body after use of a laser apparatus;

Figure 12 is a cross-sectional schematic view of an apparatus for deep drawing a cup-shaped body;

Figures 13a and 13b are enlarged cross-sectional views of portions of the apparatus of Figure 12;

Figures 14a and 14b are cross-sectional views of a second upper tool of the apparatus of Figure 12; Figure 15 is a cross-sectional view of a cup-shaped body formed using the apparatus of Figure 12;

Figure 16 is an enlarged view of a portion of Figure

15;

Figure 17 is a picture of a cup-shaped body formed using the apparatus of Figure 12;

Figure 18 is a cross-sectional view of a portion of the base of a cup-shaped body after formation by the apparatus of Figure 12;

Figure 19 is a cross-sectional view of another

apparatus showing the formation of a thinned first portion in a base of a cup-shaped body;

Figure 20 is an enlarged view of a section of Figure

19;

Figure 21 is a cross-sectional view of another example of capsule according to the present disclosure; and

Figure 22 is a schematic illustration of a detail of the capsule of Figure 21 with an enclosing member of a beverage preparation machine in a closed position.

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 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. 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 5 - 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 5 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 .

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 an inner face the aluminium layer 71. The lacquer layer (not shown in Figures 5 and 6) may have a thickness of about 10 microns. 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 one example, shown schematically in Figure 6, 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 74 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 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 base 42 of the cup-shaped body 40 is provided with a first portion 60 which is thinned relative to a second portion 61 of the base 42 such that the thickness of the one or more polymers layers 72 in the first portion 60 is less than in the second portion 61. The entire thickness of the one or more polymer layers 72 may be removed within the first portion 60.

However, more typically some thickness of polymer material will remain within the first portion 60. Preferably, the total thickness t_p of the one or more polymer layers 72 is reduced by 40% or greater, more preferably by 60% or

greater. The process of thinning the one or more polymer layers 72 may, optionally, also produce thinning of the aluminium layer 71.

The first portion 60 of the base 42 forms a weakened zone of the base 42 which may be more easily pierced by the perforation elements 14 (also known as piercers) .

The first portion 60 which is thinner may be created in a number of ways which will be described below. However, in each case the first portion 60 of the base 42 is made thinner by displacing or removing at least a portion of the one or more polymer layers 72.

Advantageously, the first portion 60 of the base 42 may be located on the base 42 so as to align with the one or more perforation elements 14 of the beverage preparation machine so that piercing in use of the beverage capsule 1 will be through the first portion 60 of the base 42. To this end it is desirable that the first portion 60 extends across a circular path at radius Rl from the central longitudinal axis of the beverage capsule 1. The first portion 60 preferably comprises an annular region of the base 42 as shown in Figure 2 but may

alternatively be a circular region also encompassing a centre of the base 42. The annular region of the base 42 may have a width in the radial direction of 1.5 to 3.0mm. In one example, an inner edge of the annular region may be located 5-6mm from a central longitudinal axis of the cup-shaped body 40 and an outer edge of the annular region may be located 7-8mm from the central longitudinal axis.

The displacement of at least a portion of the one or more polymer layers 72 from the first portion 60 of the base 42 may form (as will be described further below) one or more raised ribs 63, wherein the raised ribs 63 have a thickness t_r greater than the thickness tb of the second portion 61 of the base 42. The one or more raised ribs 63 may be formed at an inner and/or outer interface between the first portion 60 and the second portion 61 of the base 42. The one or more raised ribs 63 may be formed on an outer and/or an inner face of the base 42.

The raised ribs 63 may have a thickness t_r of greater than 200 microns, preferably greater than 300 microns.

As noted above, the base 42 comprises a first portion 60 which is thinner that a second portion of the base 42.

A first method for displacing or removing at least a portion of the one or more polymer layers 72 to produce the first portion 60 will now be described with reference to Figures 7 to 10. In this method the first portion 60 is made thinner by applying a heated tool 90 to the base 42. As shown in Figure 7, the heated tool 90 may comprise an annular element terminating in a downwardly-facing annular working surface 92. The annular working surface 92 may be canted to the horizontal so as to math a corresponding angle of the portion of the base 42 to which it will be applied. The heated tool 90 is mounted in an upper rig 91 and the cup-shaped body 40 is supported on the inside by a support pommel 93.

The heated tool 90 is heated to a temperature of 250 to

300°C and applied to the base 42 with a force of 500 to 1000N. The contact time between the heated tool 90 and the base 42 may be relatively short, for example, for 0.1 to 0.6 seconds, preferably 0.3 seconds.

The heat and pressure from the heated tool 90 causes the polymer material of the one or more polymer layers 72 to soften and/or melt and therefore flow (or otherwise be displaced) causing a thinning of the first portion 60 and preferably the formation of the raised ribs 63 as discussed above and as shown in the picture of Figure 9 which shows the thinner annular first portion 60 bounded on each side by a raised rib 63. Figure 10 shows a cross-sectional view through an example of the base 42 of a cup-shaped body 40 that has been thinned according to this first method. The thickness of the polymer layer (s) 72 in the second portion 61 which has not been subjected to the heated tool 90 is approximately 100 microns. The thickness of the aluminium layer 71 is approximately 100 microns in both the first portion 60 and the second portion 61. In the first portion 60 the polymer layer 72 has been thinned down to a thickness t_t of 30 microns. The displaced polymer material has flowed to either side and formed the raised ribs 63 which have a thickness t_r of between 380 and 500 microns.

In a comparative test cup-shaped bodies 40 were formed from a laminated material comprising an aluminium layer 71 comprising aluminium alloy of grade 8011 with a thickness t_a of 100 microns and a coextruded polymer film 74 of Flextrus WB 100ET with a thickness t_p of 100 microns. A control group had no application of the heated tool 90 to their bases 42. A test group had a thinned first portion 60 formed by use of the heated tool 90 at a temperature of 280°C, with a force of 750N and for a contact time of 0.3s. The cup-shaped bodies 40 were then tested to determine the force required to pierce the base 40 using typical perforation elements 14 of a beverage preparation machine. For the control group the average maximum force to pierce the base 40 was found to be 26.89N. For the test group the average maximum force was found to have been reduced to 23.03N.

A second method for displacing or removing at least a portion of the one or more polymer layers 72 to produce the first portion 60 will now be described with reference to Figure 11. In this method the first portion 60 is made thinner by use of a laser. A narrow or wide laser beam may be used. An example of a suitable apparatus is the Firestar F-series of CO₂ lasers, available from Synrad, Inc. of

Mukilteo, WA, USA. The output power may be of the order of 40W and the power may be modulated. A flat field lens may be used. The laser wavelength may be 10.6 microns and the frequency 20kHz. A beam duration time of the order of 3 seconds may be used and the beam steered while energised to mark out the shape of the required first portion 60. The use of the laser can be used to form the one or more raised ribs 63 discussed above as the heat from the laser beam may cause some of the one or more polymer layers 72 to soften and/or melt and be displaced sideways away from the first portion 60 of the base 42 (possibly together with ablation of other material) . The material so displaced cools and

solidifies/hardens at the edges of the first portion 60 at the interface with the second portion 61 to form the raised ribs 63. Figure 10 illustrates the end result with the thinner annular first portion 60 bounded on each side by a raised rib 63.

In a further comparative test cup-shaped bodies 40 were formed as before from the laminated material comprising aluminium alloy of grade 8011 and a coextruded polymer film of Flextrus WB 100ET. A control group had no application of the laser to their bases 42. A first test group had a thinned first portion 60 formed by use of a single point laser and a second test group had a thinned first portion 60 formed by use of a wide bean laser. The cup-shaped bodies 40 were then tested. For the first test group the average maximum force to pierce was found to have been reduced to 22.48N and for the second test group the force had been reduced to 21.16N compared to the control group result of 26.89N.

A third method for displacing or removing at least a portion of the one or more polymer layers 72 to produce the first portion 60 will now be described with reference to Figures 12 to 20. In this method the first portion 60 is made thinner by mechanically squashing the first portion 60 of the base 42. A first example of the third method is illustrated in Figures 12 to 18. This example may involve two formation steps as part of a deep drawing process. A raised formation 110 is created at the location of the first portion 60 of the base 42 in a first formation step and, in a second formation step, the raised formation 110 is

squashed so as to thin the first portion 60 of the base 42 by displacing at least some of the one or more polymer layers 72.

Figure 12 illustrates a section of a deep drawing rig for forming the cup-shaped body 40. The rig comprises an upper half and a lower half. The raised formation 110 may be formed by the shaping of the tool pieces held in the upper half and the lower half. As illustrated in Figure 12 the upper half of the rig initially holds a first upper tool 96. The first upper tool 96 is shaped to configure an outer surface of the cup-shaped body 40 and is provided with an annular cavity 97 as best seen in the enlarged view of

Figure 13a. The bottom half of the rig holds a bottom tool 95. The bottom tool 95 is shaped to configure an inner surface of the cup-shaped body 40 and is provided with a raised step 94 as shown in Figure 13a. The raised step 94 of the bottom tool 95 and the cavity 97 of the first upper tool 96 together act to form the raised formation 110 of the cup- shaped body 40 as the first upper tool 96 and bottom tool 95 are brought together at the end of the first step of the drawing process at which point the cup-shaped body 40 is in an intermediate form. The interaction of the upper half and lower half of the deep drawing rig also configures the shape of the flange 70 and rim 47 as shown in the enlarged view of Figure 13b. (In an alternative mode the cup-shaped body 40 may be deep drawn by a prior operation and the first upper tool 96 and the bottom tool 95 be used subsequently just to form the raised formation 110) .

The first upper tool 96 is then swapped out in the upper half of the rig for a second upper tool 98 as shown in Figure 14a and Figure 14b. The second upper tool 98 has no cavity at the location of the first portion 60 of the cup- shaped body but rather has a continuous surface level 99. The second upper tool 98 and the bottom tool 95 are then compressed together with the intermediate form of the cup- shaped body 40 therebetween. Consequently, the raised step 94 of the bottom tool 95 and the surface level 99 of the second upper tool 98 squeeze between them the first portion 60 of the base 42 causing displacement of at least a portion of the one or more polymer layers 72 at the location of the raised formation 110 together with, optionally, thinning the aluminium layer 71.

As shown in Figure 16, the raised formation 110 may have two riser segments 110a and 110b extending upwardly from a remainder of the base 42 and a tread segment 110c spanning between the riser segments so that the raised formation 110 has a generally shallow N-shaped profile in cross-section as shown in Figure 16. Also, Figure 17 illustrates a cup-shaped body 40 after formation of the raised formation 110 and Figure 18 illustrates a cross- section through the raised formation 110 of an example cup- shaped body 40. In this example the thickness of the polymer layer (s) 72 in the second portion 61 which has not been subjected to concentrated mechanical squashing is

approximately 85 microns. The thickness of the aluminium layer 71 is approximately 100 microns in the second portion 61 which has not been squashed. In the first portion 60 the polymer layer 72 has been thinned down to a thickness t_t of 40 microns and the aluminium layer 71 has been thinned down to approximately 50 microns.

The raised formation 110 preferably has a height h of 0.18 to 0.35mm, more preferably 0.25mm above the surface of the second portion 61 as shown in Figure 16.

In a further comparative test cup-shaped bodies 40 were formed as before from the laminated material comprising aluminium alloy of grade 8011 and a coextruded polymer film of Flextrus WB 100ET. A control group had no raised

formation 110 formed therein. A test group had a thinned first portion 60 formed by use of a raised formation 110 which was then subjected to squashing. The cup-shaped bodies 40 were then tested. For the test group the average maximum force to pierce was found to have been reduced to 22.68N compared to the control group result of 26.89N.

A second example of the third method is illustrated in

Figures 19 and 20. Like features to those of the first example have been referenced using like reference numerals. In the second example, an upper tool 96' , 96' ' and a bottom tool 95' are used to mechanically squash the base 42 of the cup-shaped body 40. In this example the cup-shaped body 40 is first deep drawn using separate tooling and then

transferred onto the bottom tool 95' for mechanical

squashing. However, the mechanical squashing of this second example could take place at the same time and with the same tooling used to deep draw the cup-shaped body 40.

The upper tool may comprise two parts: an inner core 96' ' and an outer part 96' , although this is not essential and a one-piece upper tool may be used.

The face 99' of the outer part 96' of the upper tool is flat or smooth in the angled region of the base 42 as shown most clearly in Figure 20. By contrast, the angled face of the bottom tool 95' is provided with two concentric,

circumferential recesses 66' in this region which are spaced apart from one another as shown. In between the recesses 66' is provided a raised step 94' whose surface level is raised relative to a datum surface level of the bottom tool 95' away from the region of the recesses 66' and raised step 94' . In other words, the raised step 94' is raised relative to the datum surface level while the recesses 66' are recessed relative to the datum surface level.

As an example, in the case of a cup-shaped body 40 formed from a laminate having a thickness of 200 microns (for example, a 100 micron layer of aluminium and a 100 micron layer of polymer) , the recesses 66' may extend to a point 80 to 120, preferably 100 microns below the datum surface level and the raised step 94' may extend 100 to 140, preferably 120 microns above the datum surface level.

The mechanical squashing of the first portion 60 of the base 42 between the upper tool 96' , 96' ' and the bottom tool 95' forms two raised ribs 63' one to each side of the first portion 60 by squashing and displacement of the material in the first portion 60 into the recesses 66' . The raised ribs 63' border the first portion 60 and demarcate an interface between the thinner material of the first portion 60 and the thicker material of the second portion. The raised ribs 63' are also thicker than the second portion of the base 42. The two raised ribs 63' are formed on an inner face of the base 42 at the location of the recesses 66' . The outer face of the base 42 is substantially smooth in the region of the first portion 60 due to the flat, smooth face 99' of the outer part 96' of the upper tool.

As an example, in the case of a cup-shaped body 40 formed from a laminate having a thickness of 200 microns (for example, a 100 micron layer of aluminium and a 100 micron layer of polymer) the raised ribs 63' may have a thickness of 280 to 320, preferably 300 microns and the first portion 60 may have a thickness of 60 to 100 microns, preferably 80 microns. The cup-shaped body 40 away from the point of mechanical squashing may retain its thickness of 200 microns.

The mechanical squashing may also thin the aluminium layer within the first portion 60. However, the majority of the thinning of the first portion 60 will typically be due to displacement of the one or more polymer layers. For example, in the case of a laminate formed of a 100 micron aluminium layer and 100 microns of polymer (in one or more layers) the thickness of the first portion 60 after

mechanical squashing may be, for example, 100 microns, comprised of a 10 micron thickness of polymer and a 90 micron thickness of aluminium.

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 first portion 60. Preferably the perforation elements 14 only contact the thinner, first portion 60 of the base 42.

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 4, 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.

Figures 21 and 22 illustrate another example of

beverage capsule 1. Features corresponding to those of the above examples are denoted by corresponding reference signs. Features of this and the previous examples may be

interchanged and combined as desired. In addition, in the following description only differences between the examples will be described in detail. In other respects the reader is directed to the description of the prior examples.

The cup-shaped body 40 differs from that of the first embodiment in the configuration and geometry of the

outwardly extending flange 70. The thinning of the first portion 60 of the base 42 is as previously described.

The outwardly-extending flange 70 is provided with a raised ridge 80 formed from the laminate material. The raised ridge 80 is formed by bending of the laminate

material, i.e. the raised ridge 80 is a convolution in the material rather than a locally thickened region.

As shown in Figure 22, the raised ridge 80 comprises an inner wall 81 that faces the side wall 43 of the beverage capsule 1 and an outer wall 82 that faces away from the side wall 43. An apex 83 of the raised ridge 80 joins the inner wall 81 and the outer wall 82. The raised ridge 80 may have a generally triangular shape and in particular the inner wall 81 may be angled, such that an angle a at a junction between a remainder of the flange 70 and the inner wall 81 is from 90° to 120°, preferably 105°.

The apex 83 is located at a higher level relative to a remainder of the outwardly extending flange 70. The raised ridge 80 may have a height of 0.75 to 2.5 mm, preferably 1.0 to 1.5 mm, more preferably 1.3 mm.

In use, as shown in Figure 22, on closure of the enclosing member 2 a leading edge 23 of the enclosing member 2 contacts the at least one raised ridge 80 and forms a seal therewith. Figure 22 illustrates that the leading edge 23 of the enclosing member 2 may comprise an inner rim 23a and an outer rim 23b which are concentric and spaced apart from one another to define a recess 23c there between, which may be generally annular (although may have interruptions around its circumference) . Preferably, on closure of the enclosing member 2 the inner rim 23a of the leading edge 23 contacts the inner wall 81 of the raised ridge and forms a seal therewith. At the same time (or shortly thereafter) the apex 83 of the raised ridge 80 is received in the recess 23c. The raised ridge 80 (and the remainder of the flange 70) may be driven downwards by the action of the enclosing member 2 on the inner wall 81 and/or apex 83 which may cause the inner wall 81 and/or outer wall 82 to buckle and deform/crumple . In addition, as in the first example, the deformation of the laminate material due to the compressibility of the polymer layer 72 allows for the laminate material to conform to the shape of the leading edge 23. In particular the polymer layer 72 is able to fill any gaps arising due to the

presence of grooves in the leading edge 23.

Downward movement of the enclosing member 2 may

continue beyond the point illustrated in Figure 22 until the inner rim 23a contacts and bears against the remainder of the outwardly extending flange 70.

Piercing and brewing of a beverage from the beverage capsule 1 may be as described above in the first example.

Claims

Claims :

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

a) forming from a sheet of material a cup-shaped body, the cup-shaped body comprising a base, a side wall and an open mouth opposite the base;

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

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 beverage capsule and the aluminium layer is provided towards an interior of the beverage capsule;

wherein the first portion of the base is made thinner by displacing or removing at least a portion of the one or more polymer layers.

2. The method of claim 1, wherein the first portion is made thinner by displacing or removing at least a portion of the one or more polymer layers during or after step a) .

3. The method of claim 1 or claim 2, wherein the first portion of the base is intended to be pierced in use of the beverage capsule by a beverage preparation machine in which the beverage capsule can be inserted.

4. The method of any preceding claim, wherein the first portion comprises an annular or circular region of the base.

5. The method of any preceding claim, wherein the

displacement of at least a portion of the one or more polymer layers from the first portion of the base forms one or more raised ribs, wherein the raised ribs have a

thickness greater than the second portion of the base.

6. The method of claim 5, wherein the one or more raised ribs are formed at an inner and/or outer interface between the first portion and the second portion of the base.

7. The method of claim 5 or claim 6, wherein the one or more raised ribs are formed on an outer and/or an inner face of the base.

8. The method of any preceding claim, wherein the sheet of material prior to step a) has a uniform thickness.

9. The method of any preceding claim, wherein the one or more polymer layers comprises multiple polymer layers.

10. The method of any preceding claim, wherein in step a) the cup-shaped body is formed by deep drawing the sheet of material .

11. The method of any preceding claim, wherein the first portion of the base is made thinner by displacing or

removing at least a portion of the one or more polymer layers by applying a heated tool to the base.

12. The method of claim 11, wherein the heated tool has a temperature of 250 to 300°C.

13. The method of claim 11 or claim 12, wherein the heated tool is applied to the base with a force of 500 to 1000N.

14. The method of any of claims 11 to 13, wherein the heated tool is applied to the base for 0.1 to 0.6 seconds, preferably 0.3 seconds.

15. The method of any of claims 1 to 10, wherein the first portion of the base is made thinner by displacing or

removing at least a portion of the one or more polymer layers by use of a laser.

16. The method of any of claims 1 to 10, wherein the first portion of the base is made thinner by displacing at least a portion of the one or more polymer layers by mechanically squashing the first portion of the base during or after step a) .

17. The method of claim 16, wherein a raised formation is created at the location of the first portion of the base in a first step and, in a second step, the raised formation is squashed so as to thin the first portion of the base by displacing at least some of the one or more polymer layers.

18. The method of claim 17, wherein squashing of the raised formation also thins the aluminium layer of the first portion .

19. The method of any of claims 16 to 18, wherein the raised formation is a raised step, preferably having a height of 0.18 to 0.35mm, more preferably 0.25mm.

20. The method of claim 16, wherein mechanically squashing the first portion of the base forms at least one raised rib.

21. The method of claim 20, wherein the at least one raised rib are formed at an inner and/or outer interface between the first portion and the second portion of the base.

22. The method of claim 20 or claim 21, wherein the at least one raised rib are formed on an inner face of the base .

23. The method of claim 22, wherein the base is

mechanically squashed between an upper tool and a bottom tool, and the bottom tool comprises at least one recess for forming the at least one raised rib.

24. A beverage capsule comprising a cup-shaped body and a lid; the cup-shaped body having a base, a side wall and an open mouth opposite the base; the lid being sealed to the cup-shaped body to close the open mouth;

25. The beverage capsule of claim 24, wherein the first portion of the base is intended to be pierced in use of the beverage capsule by a beverage preparation machine in which the beverage capsule can be inserted.

26. The beverage capsule of claim 24 or claim 25 wherein the first portion comprises an annular or circular region of the base.

27. The beverage capsule of any of claims 24 to 26, wherein the first portion of the base comprises one or more raised ribs located at an inner and/or outer interface between the first portion and the second portion of the base, wherein the raised ribs have a thickness greater than the second portion of the base.

28. The beverage capsule of claim 27, wherein the one or more raised ribs are formed on an outer and/or inner face of the base.

29. The beverage capsule of any of claims 24 to 28, wherein the one or more polymer layers comprise multiple polymer layers .

30. The beverage capsule of any of claims 24 to 29 further containing one or more beverage ingredients.

31. A beverage producing system comprising: a beverage capsule as claimed in any of claims 24 to 30; 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.

32. The beverage producing system of claim 31, wherein the beverage preparation machine comprises one or more piercers which pierce the first portion of the base of the beverage capsule when the enclosing member is moved into the closed position .