WO2018083564A1

WO2018083564A1 - Capsule, manufacturing method, multilayer film

Info

Publication number: WO2018083564A1
Application number: PCT/IB2017/056537
Authority: WO
Inventors: Riccardo ZAMMORI; Gino TANSINI
Original assignee: Safta S.P.A.
Priority date: 2016-11-04
Filing date: 2017-10-20
Publication date: 2018-05-11
Also published as: IT201600111266A1

Abstract

Capsule (1) for the production of an infused beverage, comprising a tray-shaped body (2) open at one end, and a closure membrane (4) sealingly applied to the body (2) to close such end and comprising a multilayer film (10) at least partially impermeable to an infuser liquid for such beverage. The body (2) and the film (10) are composed of one or more compostable materials according to the standard UNI EN 13432 and/or ASTM D6400. The multilayer film (10) defines weakening depressions (6) which extend in part through its thickness (A) and are such that, upon surpassing a predetermined pressure value, such depressions (6) lacerate the film (10) to allow the passage of the infused beverage from the inside of the tray-shaped body (2) towards the outside. The invention further relates to a multilayer film (10) and a manufacturing method.

Description

DESCRIPTION

"CAPSULE , MANUFACTURING METHOD , MULTILAYER FILM"

[0001] The object of the present invention is a multilayer film for making a capsule containing an aromatic substance for the production of an infused beverage (e.g. coffee, tea, herbal teas, fruit juices, etc.), a manufacturing method for making a closure membrane, and a capsule comprising such film.

[0002] A widespread problem with the use of disposable capsules for dispensing beverages, such as coffee, mainly concerns the environmental impact thereof.

[0003] Although the first compostable containers may already be manufactured on an industrial scale and have already entered the market, the closure films associated with such containers still suffer from the drawbacks listed hereinafter.

[0004] Mainly, the known films are of two types, i.e. aluminum films and biodegradable and compostable films comprising micro-perforations.

[0005] Films of the first type may be welded on capsules of various materials and, by their metallic nature, have a very low elasticity and a high thermal stability, conditions which make them suitable to break on contact with the abutment cusps of a special infuser when the pressurized hot water exerts sufficient force from inside the capsule.

[0006] Films of the aforementioned second type, although not having physical/mechanical characteristics comparable to aluminum films, are able to dispense the beverage through the micro-perforations passing through the film itself .

[0007] Against this background, there is an increasing number of companies which, on the pressure of public opinion, require biodegradable and fully compostable capsules, enabling them to dispose of the entire used capsule (including specifically the container, the film, and the spent infused substance) in a differentiated collection of organic waste. At the same time, there is inevitably a need to have good quality dispensing, and consequently a coffee with a taste comparable to that obtained with the capsules comprising aluminum films.

[0008] In addition, it should be noted that the current compostable capsules on the market technically provide an infused beverage, but this does not occur under pressure therefore such capsules do not allow an espresso coffee of good quality to be obtained, particularly with a foam that might be called satisfactory from the quantitative and qualitative point of view.

[0009] The object of the present invention is therefore to propose a capsule capable of overcoming the preceding drawbacks .

[0010] Such object is achieved by means of a capsule according to claim 1, through a method according to claim 17, and by means of a multilayer film according to claim 18. The dependent claims show advantageous or preferred embodiments .

[0011] The features and advantages of the capsule according to the present invention will be apparent from the following description, given by way of a non-limiting example, of its preferred embodiments according to the accompanying drawings. In said drawings:

[0012] - figure 1 shows a front perspective view of a capsule, object of the present invention, according to a possible embodiment;

[0013] - figure 2 shows a schematization of a section of a multilayer film object of the present invention, according to an illustrative embodiment usable as the membrane of a capsule according to the present invention;

[0014] - figures 3-6 schematize plan views of closure membranes according to various embodiments of the present invention, wherein the possible shapes and distributions of the depressions are illustrated.

[0015] In the following description, the elements of capsule 1 and multilayer film 10 according to the invention common to the various embodiments described will be indicated with the same numerical references.

[0016] With reference to the numbering of the attached tables, a capsule for dispensing an infused beverage is indicated in its entirety at reference number 1.

[0017] In a general embodiment, such capsule 1 comprises a tray-shaped body 2 open at one end and which, according to different variants, may be substantially cylindrical or frusto-conical .

[0018] Specifically, the tray-shaped body 2 delimits an inner compartment (not shown) for containing an aromatic substance - to be infused, preferably under pressure - for such beverage. Purely by way of example, the inner compartment may contain coffee powder.

[0019] The capsule 1 further comprises a closure membrane 4 sealed to the tray-shaped body 2 to close the open end and which comprises a multilayer film 10 at least partially impermeable (for example: completely impermeable) to an infuser liquid for the beverage in question. According to one variant, the infuser liquid may be water or milk.

[0020] In one embodiment, the closure membrane 4 is welded or glued to the tray-shaped body 2, and in particular to an annular rim 24 (preferably protruding outwardly from the inner compartment) which delimits the open end of such body. [0021] Advantageously, the annular rim 24 is suitable to abut against a support surface surrounding an infusion chamber of an infusion assembly when the capsule is properly inserted into such chamber.

[0022] According to various embodiments, the tray-shaped body 2 could be made of a cellulose-based material, or a sheet of paper or paper material.

[0023] Advantageously, the tray-shaped body 2 is integrally made in one piece with the annular rim 24.

[0024] "Paper material" means not only the commonly used material based on wood or cellulose pulp, but also made from other fibers such as cotton, linen and hemp, as well as, of course, recycled paper.

[0025] The tray-shaped body 2 and the multilayer film 10 are entirely composed of one or more compostable materials according to the standard UNI EN 13432 and/or ASTM D6400. It should be noted that the reference date of these standards is that in force on the date of priority of this patent application.

[0026] According to one variant, the multilayer film 10 could comprise a first support layer 8, and a plurality of second, biodegradable and compostable polymer layers 12, 14, 16, joined through the thickness A of the multilayer film 10.

[0027] According to one variant, the first support layer 8 may comprise or consist of paper or cardboard, or another suitable biodegradable and compostable material.

[0028] For example, the first support layer may be of a thickness between 50 and 190 μπι.

[0029] According to possible embodiments, the multilayer film 10 may comprise one or more second layers 12, 14, 16 comprising or consisting of one or more of:

[0030] i) a material 12 comprising a crystalline phase comprising amylose and an amorphous phase comprising amylopectin;

[0031] ii) a material 14 comprising or consisting of poly- lactic acid (PLA) ;

[0032] iii) a gas and/or moisture barrier biomaterial 16.

[0033] According to an advantageous variant, the multilayer film 10 comprises all the aforementioned second layers 12, 14, 16.

[0034] With regard to material i) , a possible usable product is known under the trade name Mater-BI®, marketed by the company Novamont S.p.A. (Novara-Italia) .

[0035] Regarding, on the other hand, the material iii) , a possible usable product is known under the trade name Natureflex®, marketed by the company Innovia Films.

[0036] According to a possible arrangement of such layers, the capsule 1 could comprise a second layer 12 of the material i), fixed to the first support layer 8, and second layers 14, 16 of the materials ii) and iii) , arranged between the second layer 12 of the material i) and the tray-shaped body 2.

[0037] The multilayer film 10 delimits one or more weakening depressions 6 that extend in part through its thickness A.

[0038] According to possible embodiments, the multilayer film 10 has a thickness A within the range of 60-300 μπι, optionally 100-280 μπι, and for example 120-260 μπι.

[0039] Advantageously, one or more weakening depressions include notches or incisions of the multilayer film 10.

[0040] Such one or more weakening depressions 6 are shaped in such a way that, upon exceeding a predetermined pressure value, such one or more depressions 6 lacerates the film 10 to allow the passage of the brewed beverage from the inside of the tray-shaped body 2 outwards.

[0041] In other words, the multilayer film 10 is designed to maintain its integrity below the predetermined pressure value. However, above this value, the weakening depression 6, or plurality thereof, constitutes at least one preferential or programmed tear point of the closure membrane so that the film 10 is lacerated and the infused beverage may escape from the capsule 1.

[0042] More specifically, when the capsule 1 is introduced into the infusion chamber, the closure membrane 4 is substantially integral so as to preserve the fragrance and aroma of the aromatic substance.

[0043] On the contrary, during the infusion, the infuser liquid is introduced under pressure in the inner compartment, for example by means of a male infuser entering the capsule 1 through a wall of the tray-shaped body 2 to infuse the aromatic substance.

[0044] When the continuous introduction of the infuser liquid into the capsule increases the value of the pressure above the predetermined pressure value, the weakening depression 6 or the plurality thereof will produce slits passing through the thickness A for the infused beverage to flow out.

[0045] According to a preferred variant, the depth, the density and/or extension of such one or more weakening depressions 6 are selected so that the laceration of the multilayer film 10 is caused by exceeding the predefined pressure value inside the tray-shaped body 2, i.e. solely as a result of the pressure, in the absence of mechanical means for perforating such film 10.

[0046] According to a further variant, the weakening depression 6 or plurality thereof passes completely through all the layers 8, 12, 14, 16 of the multilayer film 10 with the exception of one 8, or passes completely through only some of the layers 8, 12, 14, 16 of such film 10.

[0047] In other words, a layer (e.g. the first support layer 8) of the multilayer film 10 is only partially crossed by this weakening depression 6 or plurality thereof. Optionally, at least one other layer 12, 14, 16 may have no weakening depressions 6.

[0048] Therefore, according to different variants, only one layer of the multilayer film 10 may be partially "intact" (i.e. not crossed by the weakening depression 6 or by the plurality of depressions), or at least one layer of such film 10 may be completely intact.

[0049] For example, the thickness of intact material of the single layer 8 or the multilayer film 10 could be within the range of 40-95 μπι, optionally 40-80 μπι, and for example 40-50 μπι.

[0050] According to an advantageous variant, the weakening depression 6, or the plurality thereof, is adjustably positioned in a weakening zone 18 of the multilayer film 10.

[0051] It should be noted that within the present description, the term "adjustably" means positioning the groove 6 on the film 10 with a specific shape and arrangement .

[0052] In particular, the weakening depression 6 or the plurality thereof may be provided internally to the external contour 38 of at least one closure membrane 4.

[0053] By way of example, the weakening zone 18 could comprise a maximum thickness band of about 25 millimeters, about 30 millimeters or about 35 millimeters .

[0054] According to a further variant, an inner surface 20 and/or an outer surface 22 of the multilayer film 10 is at least partially covered by a superficial barrier layer with respect to gas and/or humidity, such as a metal layer. Preferably, the superficial barrier layer also partially delimits one or more weakening depressions 6 through its own thickness.

[0055] With reference to the variants shown in figures 3 to 6, hereinafter possible configurations of the weakening depressions are shown.

[0056] In each of these figures, the layout and the external contour 38 of the first closure membrane 4 of a row are shown on the left, without further indicating the presence of the other membranes arranged progressively on the right (in the direction of extension of the lines 26 for the variant of figure 3, and in that same direction for the subsequent variants) .

[0057] According to a first embodiment (figure 3 or figure 5), the weakening depressions 6 extend in the form of substantially parallel continuous lines 26, for example spaced about 1.5 millimeters, about 3.0 millimeters, or a distance within the range of 1.0-3.5 millimeters.

[0058] Optionally, in the space 28 comprised between each pair of continuous lines 26, incident or orthogonal branches 30 extend. According to an advantageous variant, such branches 30 are connected to one or the other continuous line alternately along the direction of extension of one of such lines (figure 5) .

[0059] For example, the maximum length of the branches 30 could be about 2 millimeters or 1.5 millimeters.

[0060] According to a second embodiment, the weakening depressions 6 extend in the form of micro-holes 32 distributed along the inner 20 or outer 22 surfaces of the multilayer film 10 with a minimum predetermined distance of each micro-hole from each adjacent micro- hole .

[0061] For example, such minimum predetermined distance could be about 0.5 millimeters, about 1 millimeter, or about 1.5 millimeters.

[0062] According to a third embodiment, the weakening depressions 6 extend in the form of crosses 34 distributed along substantially parallel pathways of the multilayer film 10.

[0063] Optionally, one or more groups of four crosses 34 may have a cross 36 in a substantially interstitial position. Preferably, the interstitial cross 36 is rotated about 45° with respect to the orientation of the other four crosses 34.

[0064] For example, one or more crosses could have a size of about 2 x 2 mm.

[0065] According to a further example, the substantially parallel paths of the crosses 34 may be spaced about 4 millimeters .

[0066] According to a variant, the crosses 34 (or 36) could be spaced about 4 millimeters.

[0067] The aforementioned objectives are also achieved by means of a method for manufacturing a closure membrane 4 for a capsule 1 according to any one of the preceding claims, comprising the steps of:

[0068] - feeding a multilayer film (10) preferably in the form of a continuous strip;

[0069] - adjustably cutting or die-cutting such film 10 to obtain external contours 38 of a plurality of closure membranes 4, and making one or more weakening depressions 6 in the thickness A of each of such membranes.

[0070] According to one variant, contours and depressions are obtained in a single operation of cutting or die- cutting, in particular by means of a cutting or die- cutting operation referred to as a "kiss cut".

[0071] According to a further variant, the contours and the depressions are obtained in at least two successive operations of cutting or die-cutting.

[0072] The aforementioned objects are also achieved by means of a multilayer film 10 for making a closure membrane 4 of a capsule 1.

[0073] Since a preferred variant requires that such multilayer film 10 be used in the capsule 1 as described above, even if it is not expressly indicated, such film 10 may comprise any one of the aforementioned features.

[0074] Such multilayer film 10 is at least partially impermeable to an infuser fluid for an infused beverage and is wholly constituted by one or more compostable materials according to the standard UNI EN 13432 and/or ASTM D6400.

[0075] The multilayer film 10 delimits one or more weakening depressions 6 which extend in part through its thickness A and are such that, upon exceeding a predetermined pressure value, such one or more depressions 6 lacerate such film 10.

[0076] Innovatively, the capsule, the method and the multilayer film object of the present invention allow the drawbacks related to the prior art to be fully overcome.

[0077] More specifically, the introduction of predefined weaknesses on the biodegradable and compostable closure membrane allows the breakage of the membrane itself to be programmed according to the pressures expected within the capsule in a simple and economical way.

[0078] Thus, the membrane may also be manufactured using compostable raw materials with no loss of aroma and quantity of foam in the infused beverage, so that a spent capsule according to the present invention may be recycled as is in the collection of organic waste.

[0079] Advantageously, the present invention allows pressures inside the capsule comparable to aluminum films according to the prior art to be obtained.

[0080] Without wishing to provide a scientific explanation for the phenomenon, it is believed that the greater internal pressures obtained with this capsule and this film are due to the careful selection of the features of the material integral to the multilayer film.

[0081] Advantageously, the present invention has allowed for a simple and inexpensive way to introduce weaknesses in the multilayer film, and wherein the fissures generated above the predetermined pressure are programmable in an extremely versatile way.

[0082] Advantageously, the present invention has allowed raw materials to be defined which allow - from a technological-productive point of view - an easy-to- process multilayer film to be obtained.

[0083] Advantageously, the present invention has allowed for good barriers to oxygen and/or humidity, but without compromising the essential biodegradability and compostability .

[0084] To the embodiments of the multilayer film, of the method and of the capsule according to the invention, a person skilled in the art may, to satisfy contingent needs, make modifications, adaptations and substitutions of some elements with others that are functionally equivalent, without departing from the scope of the following claims.

[0085] Each of the features described as belonging to a possible embodiment may be implemented independently by the other described embodiments.

Claims

1. Capsule (1) for the production of an infused beverage, comprising a tray-shaped body (2) open at one end, and a closure membrane (4) sealingly applied to said body (2) to close said open end and comprising a multilayer film (10) at least partially impermeable to an infuser liquid for said beverage;

wherein the tray-shaped body (2) and the multilayer film (10) are entirely composed of one or more compostable materials according to the standard UNI EN 13432 and/or ASTM D6400;

and wherein the multilayer film (10) defines one or more weakening depressions (6) which extend in part through its thickness (A) and such that, upon surpassing a predetermined pressure value, said one or more depressions (6) lacerate said film (10) to allow the passage of the infused beverage from the inside of the tray-shaped body (2) towards the outside.

2. Capsule according to the preceding claim, wherein the depth, the density and/or extension of said one or more weakening depressions (6) are selected so that the laceration of the multilayer film (10) is caused by exceeding the predefined pressure value inside the tray- shaped body (2), in the absence of mechanical perforation means of said film (10) .

3. Capsule according to any one of the preceding claims, wherein the weakening depression (6) or plurality thereof completely crosses all the layers (8, 12, 14, 16) of the multilayer film (10) with the exception of one (8), or completely crosses only some of the layers (8, 12, 14, 16) of said film (10) .

4. Capsule according to any one of the preceding claims, wherein a layer (8) of the multilayer film (10) is crossed only in part by said weakening depression (6) or plurality thereof and wherein - optionally - at least one other layer (12, 14, 16) is devoid of said depressions (6), the thickness of the whole multilayer film material (10) being in the range of 40-95 pm, optionally 40-80 pm, for example 40-50 pm.

5. Capsule according to any of the preceding claims, wherein the weakening depression (6) or plurality thereof are adjustably positioned in a weakening zone (18) of the multilayer film (10), said weakening zone (18) comprising for example a band of a maximum width of about 30 mm. 6. Capsule according to any one of the preceding claims, wherein the multilayer film (10) comprises a first support layer (8), for example of 50-190 pm thick, and a plurality of second, biodegradable and compostable polymer layers (12, 14, 16), joined through the thickness (A) of the multilayer film (10) .

7. Capsule according to the preceding claim, comprising one or more second layers (12, 14, 16) comprising or consisting of one or more of:

i) a material (12) comprising a crystalline phase comprising amylose and an amorphous phase comprising amylopectin;

ii) a material (14) comprising or consisting of poly- lactic acid;

iii) a barrier biomaterial (16) of gases and/or moisture. 8. Capsule according to the preceding claim, comprising a second layer (12) of the material i) fixed to the first support layer (8), for example in paper or cardboard, and second layers (14, 16) of the materials ii) and iii) placed between the second layer (12) of the material i) and the tray-shaped body (2) .

9. Capsule according to claims 3 and 6, wherein the first support layer (8) is only partially crossed by said one or more weakening depressions (6) .

10. Capsule according to any one of the preceding claims, wherein an inner surface (20) and/or an outer surface

(22) of the multilayer film (10) is at least partially covered by a superficial barrier layer with respect to gas and/or moisture, for example a metal layer, the superficial barrier layer delimiting in part one or more weakening depressions (6) through its thickness.

11. Capsule according to any of the preceding claims, wherein :

- the multi-layer film (10) has a thickness (A) comprised in the range 60-300 pm, optionally 100-280 pm, for example 120-260 pm;

- the tray-shaped body (2) is integrally made in one piece with a projecting annular rim (24); and/or

- the tray-shaped body (2) is made from a cellulose-based material .

12. Capsule according to any of the preceding claims, wherein the weakening depressions (6) extend in the form of continuous lines (26) substantially parallel to each other, spaced apart, for example, by about 1.5 mm or 3.0 mm .

13. Capsule according to the preceding claim, wherein incident or orthogonal branches (30) extend in the space (28) comprised between each pair of continuous lines (26), said branches (30) being connected to one or the other continuous line alternately along the direction of extension of one of said lines.

14. Capsule according to any of the claims 1-11, wherein the weakening depressions (6) extend in the form of micro-holes (32) distributed along the surface of the multilayer film (10), with a predetermined minimum distance of each micro-hole relative to each adjacent micro-hole, for example of about 1 mm.

15. Capsule according to any of the claims 1-11, wherein the weakening depressions (6) extend in the form of crosses (34) distributed along substantially parallel paths of the multilayer film (10), each grouping of four crosses (34) having a cross (36) rotated by 45° in a substantially interstitial position.

16. Capsule according to any of the preceding claims, wherein one or more weakening depressions comprise notches or incisions of the multilayer film (10), and wherein the weakening depression (6) or plurality thereof constitutes at least a preferential or programmed laceration point of the closure membrane (4) .

17. Method for making a closure membrane (4) for a capsule (1) according to any of the preceding claims, comprising the steps of:

- feeding a multilayer film (10) in the form of a continuous strip;

- adjustably cutting or die-cutting said film (10) to obtain external contours (38) of a plurality of closure membranes (4), and making one or more weakening depressions (6) in the thickness (A) of each of said membranes .

18. Multilayer film (10) for making a closure membrane (4) of a capsule (1), said film (10) being at least partially impermeable to an infuser liquid for an infused beverage, and being integrally composed of one or more compostable materials according to the standard UNI EN 13432 and/or ASTM D6400;

the multilayer film (10) delimiting one or more weakening depressions (6) which extend in part through its thickness (A) and such that, upon exceeding a predetermined pressure value, said one or more depressions (6) lacerate said film (10) .