US20230026694A1 - Capsule for preparing a beverage, made of an aluminium alloy - Google Patents

Abstract

A capsule (1) designated for preparing a beverage upon injection of liquid into the capsule by means of a beverage machine, comprises a cup-shaped body (10) and a closing lid (11) through which the beverage is to be dispensed, said closing lid (11) being sealed on said body (10) and defining therebetween an inner volume for holding beverage preparation ingredients, such as ground coffee. The capsule (1) is made of an aluminium alloy of the series 3xxx, and preferably of the aluminium alloy 3004 or 3104. Use for improving the sustainability of the capsules for beverage preparation.

Description

FIELD OF THE INVENTION
• The invention relates to a capsule comprising a food product such as a beverage preparation ingredient for the preparation of beverages. In particular, the invention concerns a capsule made from metallic material such as aluminium. More particularly, the invention concerns single-use capsule made from metallic material such as aluminium.
• The invention also related to the use of a capsule made from a specific metallic aluminium material for improving the sustainability of single-use capsules for beverage preparation
BACKGROUND OF THE INVENTION
• It is known to prepare beverage, and notably coffee drinks by using a capsule containing coffee in a dispensing beverage machine. The capsule has an inner volume in which ground coffee is stored and in which a beverage or drink is produced when water is introduced inside.
• Such a capsule, designated for preparing a beverage upon injection of liquid into the capsule, comprises a cup-shaped body and a closing lid through which the beverage is to be dispensed.
• The closing lid is sealed on the body for defining therebetween the inner volume for holding beverage preparation ingredients, such as ground coffee.
• Capsules for preparation of a food product such as a beverage are widely known in the market. Often, these capsules are single-use and are made of aluminium. Most specifically, these capsules are up to now made of an aluminium alloy, itself made from mostly primary (virgin) aluminium, to which a small percentage of alloying elements is added.
• The manufacturing process of aluminium capsules uses flat, lacquered, aluminium foil, which is formed into the shape of a capsule using a deep drawing process. This manufacturing process is well-known to the skilled person.
• Even if several types of aluminium capsules exist on the market, these capsules, beside the difference in shape, all make use of a specific aluminium grade, alloy 8011A, as defined in the standards DIN EN 602:2004 and DIN EN 573-3:2013.
• This specific aluminium alloy allows good performances of formability (easy forming of the capsule during the manufacturing process). It is also adequate regarding perforability (easy perforation of the capsule) of the capsule in the dispensing beverage machine for injecting a liquid into the capsule.
• Alloy 8011A is a quite pure aluminium alloy, with low amount of alloying elements. Producing such aluminium alloy using recycled post-consumer scrap sources is rather difficult, making in turn rather difficult to produce aluminium capsules using such recycled sources.
• In most cases, the collected capsules after use are merged with other less pure aluminium scrap, and therefore recycled aluminium for alloy 8011A for manufacturing capsules is practically not available in the market.
• Indeed, as soon as a mix of alloys happens, the resulting material can not anymore, in practical terms, be reconverted into a purer aluminium alloy such as 8011A which is currently needed for the capsule manufacturing.
• It is therefore an object of the present invention to provide an improved capsule which overcomes the disadvantages of the prior art solutions.
• More specifically, the present invention aims to provide a capsule in an eco-responsible and sustainability approach, by limiting the quantity of material used for manufacturing such capsules.
• This object is solved by the independent claim. The dependent claims define further preferred embodiments of the invention.
SUMMARY OF THE INVENTION
• The invention concerns a capsule designated for preparing a beverage upon injection of liquid into the capsule by means of a beverage machine, the capsule comprising a cup-shaped body and a closing lid through which the beverage is to be dispensed, said closing lid being sealed on said body and defining therebetween an inner volume for holding beverage preparation ingredients, such as ground coffee.
• The proposed capsule is made of an aluminium alloy of the series 3xxx, and preferably of the aluminium alloy 3004 or 3104.
• Thus, by shifting from the current aluminium alloy 8011A to an aluminium alloy of the series 3xxx, the manufacturing of the capsules uses an aluminium alloy which is widely used worldwide, notably the alloy 3104 used for beverage cans.
• Due to this change of materials, one makes use of the huge market of recycled aluminium, notably from beverage cans, for the production of beverage capsules.
• Another benefit will be as well to possibly recycle the aluminium recovered from used capsules in the same recycling stream of beverage cans and to make use of the existing widespread collecting system of aluminium cans.
• The existing collecting system and recycling of aluminium may be performed provided the capsule content (beverage ingredients) is separated from the capsule body.
• All these benefits would improve the sustainability of the aluminium capsule, by reducing its environmental impact.
• In practice, the body of the capsule is provided with a sidewall and a bottom through which liquid is to be introduced.
• Preferably, the thickness of the aluminium alloy in the bottom and the sidewall of the body is comprised between 50 to 100 micrometres, and preferably between 60 and 90 micrometres.
• In an advantageous way, the thickness of the aluminium alloy is comprised between 90 and 100 micrometres.
• Due to the higher strength of the aluminium alloy of the series 3xxx, it is possible to downgauge the aluminium from the current thickness of the body of the capsule, around 100 micrometres, to a lower thickness, less than 95 micrometres, and preferably less than 90 micrometres.
• Therefore, it is possible to use lower aluminium gauge by keeping the same or better performances in the beverage machine, with less deformation of the body or the bottom of the capsule, and during product transport by reducing damage during transport (like marks and indents).
• This reduces the aluminium material consumption, the costs and the environmental impact of the capsules.
• In practice, the thickness of the closing lid is comprised between 20 and 60 micrometres.
• Another benefit of the increased strength is that when downgauging the aluminium, it is not necessary to add corrugations or ribs to the body of the capsule to achieve enough stiffness in the capsule.
• Even without corrugations or ribs, the capsule has sufficient stiffness to resist to the extraction process during operation of the beverage in the dispensing beverage machine, and to avoid damages during transport and distribution of finished goods.
• In one embodiment, the shape of the body is frustoconical, with an inclined sidewall and a bottom dome-shaped. In the proposed embodiment, the current iconic design of the Nespresso® capsule may be kept.
• In one embodiment, the body comprises a flange, the closing lid being sealed on said flange.
• Preferably, the closing lid is flat.
• A well-known frustoconical design of the capsule, without ribs or corrugations on the body, may be thus kept.
• In one embodiment, the flange comprises sealing means.
• In a further embodiments, the sealing means are formed integrally with the flange.
• In practice, the body of the capsule is made from a unique foil of aluminium alloy, for example by stamping or drawing.
• Preferably, the capsule is made of a recycled aluminium alloy.
• Thus, not only the aluminium alloy used for manufacturing the capsule is recyclable but also the capsules may be manufactured from recycled aluminium alloy.
• The sustainability of the global system of preparation of beverages from capsules, and notably coffee drinks, is improved.
BRIEF DESCRIPTION OF THE DRAWINGS
• Additional features and advantages of the present invention are described in, and will be apparent from, the description of the presently preferred embodiments which are set out below with reference to the drawings in which:
• FIG.1 is a perspective side view of a capsule according to a first embodiment of the invention;
• FIG.2 is a side view of a capsule according to a second embodiment of the invention; and
• FIGS.3A and3B are a partial enlarged sectional side views of the capsule according toFIG.2, cooperating with an engagement member of a beverage preparation machine, before and after engaging with each other.
DETAILED DESCRIPTION OF THE INVENTION
• In the following detailed description, reference is made to the accompanying drawings. However, the illustrative embodiments described in the detailed description and drawings are not meant to be limiting. Other embodiments may be utilized and other changes may be made, without departing from the scope of the claimed subject-matter presented here.
• It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures may be arranged, substituted, combined and designated in a wide variety of different configurations, all of which are explicitly contemplated and make part of this disclosure.
• In the drawings, similar symbols and references typically identify similar components, unless context dictates otherwise.
• As used in this specification, the words “comprises”, “comprising” and similar words are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean including but not limited to.
• FIG.1 illustrates acapsule1 according to a first embodiment of the invention.
• Thecapsule1 comprises a cup-shapedbody10 and a closinglid11.
• The closinglid11 is sealed on thebody10 so that the capsule is perfectly closed.
• Thebody10 and the closinglid11 form an inner volume in which a beverage preparation ingredient, in particular coffee, is stored.
• Thebody10 has a three-dimensional shape. Three-dimensional shape shall mean that the body is “formed” or in other words that the body is not flat. Thebody10 has a frustoconical shape extending around a vertical revolution axis Y. Thebody10 has a bottom101 and asidewall102. Thesidewall102 is slightly inclined with respect to the vertical revolution axis Y. The inclination angle is inferior to 45° and preferably inferior to 30°.
• Finally, the capsule presented inFIG.1 has a frustoconical shape and presents the iconic Nespresso® capsule design.
• In another embodiment, thesidewall102 can extend substantially perpendicularly to the bottom101.
• Here, the bottom101 is dome-shaped. Of course, the bottom101 could be flat.
• As known, the bottom101 may serve as an injection face during a beverage preparation process, which may be opened by dedicated injection members (knives, needles) of a beverage preparation machine.
• Thebody10 comprises a peripheral edge surrounding thesidewall102 and forming aflange103.
• The closinglid11 is flat. In other words, the closinglid11 extends substantially in one plane. The closinglid11 is sealed on theflange103, at the end opposite to the bottom101.
• The closinglid11 fits closely thebody10 so that a perfect sealing of thecapsule1 is ensured. Thecapsule1 is impermeable to liquids and moisture. Preferably, thecapsule1 is also impermeable to gas.
• The bonding of thebody10 and the closinglid11 can be obtained, but not limited to, by heat sealing or ultra-sonic sealing.
• Moreover, in order to obtain an effective fluid tightness between thecapsule1 and the beverage preparation machine during extraction of the beverage, it is known to provide theflange103, on the face opposite to the closing lid, with sealing means.
• In the embodiment ofFIG.1, theflange103 is provided with a peripheral seal (not represented) located between thesidewall102 and theflange103.
• The peripheral seal is in the form of a polymeric seal such as a rubber or silicone ring.
• FIGS.2,3A and3B illustrate a capsule according to another embodiment of the invention.
• Comparing to the first embodiment described hereunder, in this second embodiment, thecapsule1 is provided with an enhanced integrally formed sealing member, avoiding the use of a rubber or silicone seal on theflange103.
• As for the first embodiment, thecapsule1 comprises a cup-shapedbody10. Thebody10 comprises a bottom101 and asidewall102.
• As shown onFIG.2, thecapsule1 further comprises aflange103, which is preferably arranged at an open end of thebody10, opposite to the bottom101. Theflange103 extends radially outwardly from thesidewall102 of thebody10. Theflange103 is preferably arranged transversally to the vertical rotational axis Y of thecapsule1 and presents a curledouter edge103cat its extremity opposite thebody10.
• At the open end of thecapsule body10, a closinglid11 may be arranged. The closinglid11 is preferably connected to theflange103. As presented inFIGS.3A and3B, the closinglid11 is preferably connected to at least one lowerannular surface103bof theflange103, which surface103bis directed away from thecapsule body10.
• Alternatively, the closinglid11 may be connected to thebody10 or to both thebody10 and theflange103.
• Theflange103 comprises an integrally formed sealingmember104 which is arranged at an upperannular surface103aof theflange103. Theannular surface103ais arranged opposite to thesurface103bto which the closinglid11 is connected. Theannular surface103ais thus facing away from the open end of thebody10 of thecapsule1.
• The sealingmember104 is positioned between thecapsule body10 and theflange103. It comprises adedicated surface104 located at the junction between thesidewall102 of thebody10 and theflange103.
• In this embodiment, thededicated surface104 comprises astep104aextending from thesidewall102 over theflange103, thestep104abeing substantially parallel to the flange direction. Thestep104ais integrally formed with theflange103 and thebody10. This means that it is formed of same material as the flange-like rim103 and as thebody10.
• In this embodiment, the cup-shapedbody10, theflange103 and the sealingmember104 are integrally formed, i.e. by one single piece made from the same material. Accordingly, the cup-shapedbody10, theflange103 and the sealingmember104 can be manufactured from the same material by a conventional forming process. In particular, thebody10, theflange103 and the integrally formed sealingmember104 can be formed in a deep-drawing process. The deep drawing process may require more than one deep drawing step to properly form from a flat piece of material, preferably a metal sheet, the body of the capsule and the sealing member.
• As can be seen inFIGS.3A and3B, thestep104ais arranged to engage with a sealingsurface21aof acapsule engagement member21 of the beverage preparation machine (the whole machine is not represented, only a part of theengagement21 being visible inFIGS.3A and3B).
• As known, a beverage preparation machine is designed to provide heated and/or pressurized liquid into the capsule for preparing a beverage upon interaction of the liquid with the ingredients held within the capsule.
• The beverage preparation machine preferably comprises a pump, heating and/or cooling means, a liquid supply such as a water tank and/or a beverage brewing chamber for selectively receiving a capsule in order to prepare a beverage therefrom.
• The brewing chamber comprises a capsule engagement member which is designed to house a capsule and in particular the capsule body when the capsule if provided/introduced into the machine.
• During the extraction process, theengagement member21 of the beverage preparation machine, as presented inFIGS.3A and3b, is engaged with thecapsule1. Theengagement member21 preferably comprises an essentially hollow bell-shaped engagement member for receiving thecapsule body10 therein. When thecapsule1 is placed into the beverage preparation machine, theengagement member21 will be lowered onto thecapsule1 by means of a dedicated closing force.
• Theengagement member21 comprises a sealing profile presenting several sealingsurfaces21a,21band21c. The sealing surfaces are located on an inner part of theengagement member21, on a portion of theengagement member21 that comes into contact with thecapsule1. The sealing surfaces, for example, may be in the form of an annular lower surface with rounded inner and outer circumferential edges, a flat surface that in use is parallel to thesidewall102 of thecapsule1.
• FIGS.3A and3B present partial enlarged sectional side views of the embodiment of the sealingmember104 and theengagement member21 of a beverage preparation machine before and during engagement with each other.
• Particularly, when theengagement member21 is lowered from the position shown inFIG.3A onto the sealingmember104 by closing force, anannular sealing surface21aengages withstep104a.
• As a results of the force applied on the sealingmember104 in the overlap region between theengagement member21 and the sealingmember104, thestep104aof the sealingmember104 undergoes a plastically deformation during said engagement.
• The plastic deformation is due to the force that is applied:
• • by the clamping system when the coffee machine is closed through theengagement member21; and
  • during the extraction process by the water pressure through theengagement member21 on the capsule.
• Thestep104athen closely conforms with the sealing surfaces21a,21b,21cof theengagement member21 so that during the extraction process, the surface of theflange103 conforms with the shape of the sealing profile (with sealingsurfaces21a,21band21c) on the overlap portion.
• FIG.3B shows this close conformation between the sealing surfaces21a,21b,21cand theflange103 occurred during use, where thestep104aand theflange103 are deformed leading to a structure conforming the sealingmember21.
• This structure conforming the sealingmember21 produces an effective fluid tightness between thecapsule1 and the beverage preparation machine.
• Because of thedeformed flange103 conforming with the shape corresponding to the sealing surfaces21a,21b,21c, the sealing between thecapsule flange103 and theengagement member21 is increased.
• Thus, when used in the beverage preparation machine, the sealingmember104 is plastically deformed such that thecapsule1 comprises aflange103 having a new profile corresponding to the shape of the sealing profile of thecapsule engagement member21. The new profile produces an effective tightness between theflange103 and the sealing member of theengagement member21.
• The capsule according to this second embodiment enables an efficient, reliable and tolerant sealing structure made from a single integral piece and thus by omitting any additional material such as rubber.
• Of course, other embodiments of capsule could be contemplated.
• The system to which such a capsule and the beverage preparation machine are integrated in, is operated as follows for the preparation of a cup of a beverage, for example, a coffee. Thecapsule1 is placed in the beverage preparation machine and thecapsule engaging member21 is brought into contact with thecapsule1 when the beverage preparation machine is closed. The capsule is pierced on itsbottom101 by piercing means (injection needles or blades or knives, not represented) for creating the entrance of a fluid such as water (hot or cold) under pressure into thecapsule1 through the bottom101. The water wets the coffee stored inside the capsule and extracts the desired substance to form the coffee beverage.
• During the supply of the water under pressure to the capsule, the rise in pressure causes the closinglid11 to rupture (through pressing of the closinglid11 on some cover piercing means, for example) and the coffee beverage is delivered by drainage of the coffee beverage from the capsule to a cup. The beverage is thus dispensed through the closinglid11.
• The beverage preparation ingredients provided in the capsule are preferably chosen from the group consisting of roasted ground coffee, tea, instant coffee, a mixture of roasted ground coffee and instant coffee, a syrup concentrate, a fruit extract concentrate, a chocolate product, a milk-based product or any other dehydrated edible substance, such as dehydrated stock. The liquid to be used for beverage preparation is preferably water of any temperature.
• The invention seeks to provide a capsule for a beverage ingredient as described above, which is recyclable and which can be made from a recycled material.
• Thus, the capsule is made of an aluminium alloy of the series 3xxx according to the standard DIN EN 573-3.
• Preferably, the whole capsule, that is thebody10 and the closinglid11, is made of the aluminium alloy 3004 or 3104.
• For example, thebody10 is made from a unique foil of aluminium alloy and the closinglid11 is made from the same material as the one used for producing thebody10 of thecapsule1.
• According to the standard DIN EN 573-3, the aluminium alloy of the series 3xxx is an alloy having manganese as main alloying element.
• Preferably, the capsule is made of the aluminium alloy 3104, widely used for manufacturing the beverage cans.
• Aluminium alloy 3104 is used for the bodies of beverage cans, for beer and soft drinks for example.
• Thanks to the use of common aluminium alloy, as for beverage cans, sourcing of recycled aluminium for capsule production is possible.
• Thus, the capsule (body and closing lid) can be made from a recycled aluminium alloy.
• Moreover, it also allows recycling of the aluminium from used capsule in the same stream as the one used for beverage cans.
• Thus the capsules after use can be collected through the same collecting system of metal products and be sorted and recycled in the same way as the one performed for the beverage cans, provided that the beverage ingredients (coffee for example) are first separated from the capsules.
• Moreover, the aluminium alloy 3104 has a higher strength than the alloy 8011A.
• Thus, it is possible to decrease the thickness of the aluminium alloy used for producing the capsule, below an usual thickness of 100 micrometres of a standard capsule made in the alloy 8011A.
• Even with this downgauging, the capsule has enough stiffness to have good mechanical performances during use in a beverage preparation machine and as well during the transportation and distribution of the capsules.
• For this last concern, comparative tests have been performed in order to validate the product resistance during the transport.
• The resistance of the capsules may be tested for transportation both in a single packaging unit corresponding to a consumer unit (for example a sleeve with 10 capsules aligned) and in a grouping box comprising several single packaging units, for transportation on a pallet for example.
• One common test is for example a drop-test simulating a postal transport. The drop-test consists in making the single packaging unit fall several times, from a predetermined height and according to different orientations and in inspecting for damages the shape of the capsules after the fall.
• The predetermined height may be comprised between 600 and 800 mm for example.
• A comparative drop-test with standard capsules and new capsules has been performed as follows:
• Standard capsules: in aluminium alloy 8011A with a thickness of 100 micrometres.
• New capsules: in aluminium alloy 3104 with a thickness of 90 micrometres.
• One sleeve with 10 standard capsules and one sleeve with 10 new capsules have been dropped 7 times, with a drop-height of 610 mm, without opening or modifying the sleeves between the series of the7 drops.
• For each drop, different orientations of the sleeve are chosen: a specific face (lateral face of the sleeve, end face of the sleeve), or a specific corner or a specific edge is oriented face to the ground before dropping the sleeve on the ground from the predetermined height.
• The same serie of drops has been performed for the sleeve with 10 standard capsules and the sleeve with 10 new capsules.
• After the series of drops, the capsules are removed from each sleeve and verified for damages in the bottom and the sidewall of each capsule.
• Damages may be divided into 3 categories:
• • No damage
  • Low damage (a deformation less than 3 mm)
  • High damage (a deformation superior than 3 mm)
• The results are as follows:

• 	Damage in capsule bottom	Damage in capsule wall

  	No	Low	High	No	Low	High

  Standard

  	1	7	2	0	0	10
  capsules
  New capsules	2	6	2	1	4	5

• Thus, notably regarding damages in the capsule wall, new capsules in aluminium alloy 3104, even with a thickness limited to 90 micrometres, are less susceptible to transport damages in the sleeves than the standard capsules in aluminium alloy 8011A, with a thickness of 100 micrometres.
• Preferably, the thickness of the aluminium alloy in thesidewall102 and thebottom101 of thebody10 of thecapsule1 may be comprised between 50 to 95 micrometres, and preferably between 60 and 90 micrometres.
• Most preferably, the aluminium alloy has a thickness between 90 and 100 micrometres.
• Moreover, the aluminium alloy is covered by lacquers, which form an external layer on the body of the capsule. The thickness of the lacquers is comprised between 5 and 15 micrometres.
• The closinglid11 is also made in aluminium alloy 3104 and comprises a thickness between 20 to 60 micrometres.
• Moreover, the mechanical performances of the new capsules during extraction in the beverage preparation machine are the same or even better than for the standard capsules made in aluminium alloy 8011A.
• Due to the increased stiffness, the new capsules need more force to be plastically deformed as the standard one made in aluminium alloy 8011A.
• We give hereunder a comparative example of the compressive force required for deforming the capsule bottom.

• 	Compressive force needed
  	to plastically deform
  Capsule	the capsule bottom (Newton)
  Standard capsule	32N
  made from aluminium alloy 8011A.
  New capsule	57N
  made from aluminum alloy 3104

• As a consequence, when the bottom of the new capsule is pierced by the knives of the beverage machine, the deformation of the bottom around the holes created by the knives is reduced compared to the standard capsule.
• Other things being equal, the capsule height is then maintained and the knives may be introduced more deeply through the bottom into the capsule: the holes pierced by the knives may be larger, promoting the introduction of water into the capsule during the extraction of the beverage.
• Thus, the use of aluminium alloy of the series 3xxx, such as 3004 or 3014, allows maintaining the capsule stiffness, and thus the capsule shape and design even after downgauging, without a need to introduce corrugations on the capsule surface.
• The capsule may keep a frustoconical shape, with a bottom dome-shaped and inclined smooth sidewall, without corrugations or ribs.
• Thus, the current image and design of the capsule can be maintained unchanged, without ribs or corrugations on the body sidewall or the bottom.
• It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims (13)

1. A capsule designated for preparing a beverage upon injection of liquid into the capsule by means of a beverage machine, the capsule comprising a cup-shaped body and a closing lid through which the beverage is to be dispensed, the closing lid being sealed on the body and defining therebetween an inner volume for holding beverage preparation ingredients, such as ground coffee, characterized in that the capsule is made of an aluminium alloy of the series 3xxx.

2. A capsule according toclaim 1, wherein the body of the capsule is provided with a sidewall and a bottom through which liquid is to be introduced, the thickness of the aluminium alloy in the bottom and the sidewall of the body being comprised between 50 to 100 micrometres.

3. A capsule according toclaim 2, wherein the thickness of the aluminium alloy is comprised between 90 and 100 micrometres.

4. A capsule according toclaim 1, wherein the thickness of the closing lid is comprised between 20 and 60 micrometres.

5. A capsule according toclaim 1, wherein the shape of the body is frustoconical, with an inclined sidewall and a bottom dome-shaped.

6. A capsule according toclaim 1, wherein the body comprises a flange, the closing lid being sealed on the flange.

7. A capsule according toclaim 6, wherein the flange comprises sealing means.

8. A capsule according toclaim 6, wherein the sealing means are made of a peripheral seal in the form of a polymeric seal located between the sidewall and the flange.

9. A capsule according toclaim 6, wherein the flange comprises integrally formed sealing means.

10. A capsule according toclaim 1, wherein the closing lid is flat.

11. A capsule according toclaim 1, wherein the body is made from a unique foil of aluminium alloy.

12. A capsule according toclaim 1, wherein the capsule is made of a recycled aluminium alloy.

13. (canceled)

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