WO2016013002A1

WO2016013002A1 - Capsule for beverage preparation

Info

Publication number: WO2016013002A1
Application number: PCT/IL2015/050738
Authority: WO
Inventors: Gad HARIF; Reuven Nir
Original assignee: Spresso Novo Cap Ltd
Current assignee: Spresso Novo Cap Ltd
Priority date: 2014-07-24
Filing date: 2015-07-16
Publication date: 2016-01-28
Anticipated expiration: 2017-01-24

Abstract

A capsule for use in a beverage preparation machine that is adapted for containing one or more beverage ingredients is formed from a polymer material that is coated with a first layer of metal and a second layer of Silicon Oxide (Si O x ).

Description

CAPSULE FOR BEVERAGE PREPARATION

FIELD AND BACKGROUND OF THE INVENTION

The present invention, in some embodiments thereof, relates to a single use capsule for storing one or more ingredients for preparation of a beverage and, more particularly, but not exclusively, to a capsule for storing the one or more ingredients in an environment that is impermeable to oxygen and moisture.

Single use capsules containing compacted ground coffee are known for use in certain coffee preparation machines which are generally termed "espresso" machines. Capsules of this type generally include a body containing the compacted ground coffee and a membrane such as aluminum foil that seals the capsule body. Typically, the capsule body is shaped as an acute truncated cone with a rim, and the membrane is attached to the rim. Typically, the body and membrane of the capsule are formed with material to protect content stored in the capsule against moisture, oxygen and UV radiation. Some capsules are additionally packaged in external protective bags to improve resistance to moisture and oxygen ingress. When used in an "espresso" machine, the capsule is placed in a chamber where it is typically pierced on two opposing faces and hot water is passed though the capsule at relatively high pressure and temperature, thereby extracting the aromatic coffee constituents from the ground coffee to produce the coffee beverage. Typically, during operation with the "espresso" machine, the rim of the capsule is pressed against a surface in the chamber to form a sealed engagement. The sealed engagement with the chamber is typically used to insure that all of the hot water is passed through the capsule for preparation of the coffee beverage and to prevent leakage around the capsule.

U.S. Patent No. 4,136,202 entitled "Capsule for beverage preparation," the content of which is incorporated herein by reference describes a capsule containing a substance for making up a drink using an apparatus. The capsule includes a body having the general shape of an acute truncated cone with a rim and a membrane positioned over the rim to seal the capsule body. It is described that the body of the capsule is composed of sheet aluminum between 60 and 110 μ thick, preferably 80 μ with the membrane composed of aluminum, preferably between 30 and 60 μ thick. U.S. Patent No. 7,640,843 entitled "Cartridge and method for the preparation of beverages," the content of which is incorporated herein by reference describes a capsule with a body formed as a single integral piece from high density polyethylene, polypropylene, polystyrene, polyester, or a laminate of two or more of these materials. It is described that the capsule may be provided with a barrier coating to improve resistance to oxygen and/or moisture and/or other contaminant ingress. The barrier coating may be of a material selected from the group of PET, Polyamide, EVOH, PVDC or a metalized material. The barrier coating may be applied by a number of mechanisms including but not limited to vapor deposition, vacuum deposition, plasma coating, co-extrusion, in-mould labeling and two/multi-stage molding.

SUMMARY OF THE INVENTION

According to an aspect of some embodiments of the present invention there is provided a capsule body that is coated with a metal material. The coating has the advantage of providing an attractive mirror finish look to the capsule. In some exemplary embodiments, the coating improves the impermeability of the capsule body to moisture, oxygen and ultra violet (UV) radiation.

According to an aspect of some embodiments of the present invention, there is provided a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule including a capsule body being formed from a polymer material that is coated with a first layer of metal and a second layer of Silicon Oxide (SiO_x).

Optionally, the first layer is a layer of aluminum.

Optionally, the first layer is selected from a group including: a layer of nickel, chrome.

Optionally, the first and second layers provide a mirror finish look to the capsule.

Optionally, the first layer is between 100-1000 nm thick.

Optionally, the second layer is between 50-150 nm thick.

Optionally, the capsule includes a primer coated on polymer material and wherein the first layer is coated over the primer.

Optionally, the primer is silicon monoxide. Optionally, the polymer is selected from a group including: polypropylene, polyethylene, polyethylene terephthalate, amorphous polyamide, and a combination thereof.

Optionally, the first and second layers are applied on the polymer material by a physical vapor deposition process.

According to an aspect of some embodiments of the present invention, there is provided a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule being formed from a polymer material that is coated with a first layer of metal and a second layer of aluminum oxide, tin oxide, zinc oxide or a combination thereof.

Optionally, the second layer is a combination of silicon oxide and one or more of aluminum oxide, tin oxide and zinc oxide.

According to an aspect of some embodiments of the present invention, there is provided a capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule being formed from a polymer material that is coated with a layer of silicon dioxide, aluminum oxide, tin oxide, zinc oxide or a combination thereof.

Unless otherwise defined, all technical and/or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and/or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced. In the drawings:

FIGS. 1A and IB are simplified schematic perspective and cross-sectional views of a coated capsule in accordance with some embodiments of the present invention;

FIG. 2 is a simplified schematic perspective view of a coated capsule that is pre- perforated in accordance with some embodiments of the present invention; and

FIG. 3 is a simplified flow chart of a method for manufacturing a capsule in accordance with some embodiments of the present invention.

DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

Shelf life and quality of a product stored in a plastic capsule is often limited due to permeability of the capsule to oxygen, moisture and ultraviolet radiation. This is particularly the case when the capsule is used to store a ground product such as coffee or tea leaves. Capsules formed from polymer and/or plastic material are typically significantly more permeable to oxygen, moisture and UV radiation as compared to capsules formed from aluminum sheets. The present inventors have found that shelf life and quality of a product stored in a plastic capsule can be significantly improved by coating the capsule with a thin layer of metallic material and additional outer layer of Silicon Oxide (SiO_x), e.g. Si0₂. Typically, SiO_x is used to prevent oxidation of the metal coating. According to some embodiments of the present invention, the thin layer of metallic material is metal aluminum (Al). In other exemplary embodiments, an Aluminum Oxide (A1₂0₃) is used instead of the metal coating. Optionally, a nickel and/or chrome coating is used in place of aluminum. Alternatively, a SiOx coating is used without the metallic layer. Optionally, a diamond like carbon (DLC) coating is used. In some exemplary embodiments, a primary coating of silicon monoxide is applied on the capsule to improve adhesion of the metal coating. Typically, a physical vapor deposition (PVD) process, or modification of it, is applied to coat the capsule. The present inventors have found that metallic aluminum and SiO_x coating applied on an otherwise permeable material such as plastic can improve the resistance of the capsule to penetration of oxygen, moisture and UV radiation. The present inventors have found that a plastic capsule with a thin layer of metallic aluminum and SiO_x may provide a level of impermeability that is comparable to a capsule composed of sheet aluminum between 60 and 110 μ thick. Optionally, the plastic capsule with a metallic and SiO_x coating is also suitable for recycling and/or more suitable for recycling as compared to capsule formed from sheet aluminum. The present inventors have also found that the metallic and SiO_x coating over the plastic capsule is typically thin enough so that it does not interfere with the plastic recycling process. In comparison, known aluminum capsules typically include a relatively thick layer of plastic, e.g. in the order of magnitude of about 30 microns that does interfere with the process for recycling the aluminum.

Optionally, manufacturing cost for a coated plastic capsule may be lower than that for capsule composed of sheet aluminum. Optionally, the coating is not applied on the rim area of the capsule, e.g. the polymer material of the rim is left bare to enhance a fluid seal provided by the rim when engaged in a chamber of a beverage machine. The present inventors have also found that the mirror finish look provided by an outer metallic layer, e.g. aluminum, nickel and/or chrome adds an attractive feature that can aid in marketing the capsule.

Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and/or methods set forth in the following description and/or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways.

Referring now to the drawings, FIGS. 1A and IB shows a simplified schematic perspective and cross-sectional view of a coated capsule in accordance with some embodiments of the present invention. According to some embodiments of the present invention, a capsule 100 includes a body 50 defining a volume for containing a product and a rim and/or flange 20 over which a membrane 30 is attached for sealing capsule 100. According to some embodiments of the present invention, body 50 is formed from a plastic material 55 that is coated with one or more layers, e.g. layer 51, 52, 53. It is noted that the thickness of layer 51, 52, 53 and material 55 are not necessarily shown to scale. Exemplary plastics that can be used for the plastic material 55 include Polypropylene (PP), Polyethylene (PE) and Polyethylene Terephthalate (PET). Optionally, an amorphous nylon, e.g. Grivory G16 or Grivory G21 offered by EMS- Grivory, a Switzerland based company, is used for plastic material 55. Typically, the plastic body is formed by injection molding although other processes may be used.

According to some embodiments of the present invention, layer 52 is a metal layer, e.g. Al. Optionally, metal layer 52 includes a coat of metal Al that is between 10 - 3000 nm, e.g. between 100 - 400 nm or between 50 - 500 nm. In some exemplary embodiments, layer 52 is formed from nickel or chrome in place of Al. The present inventors have found that the Al layer provides a particularly good mirror finish look to the capsule. In some exemplary embodiments, when a transparent capsule is desired Aluminum Oxide Α1₂0₃ or A10_x or Silicone Oxide (SiO_x) is used in place of Al for metal layer 52. Optionally, Tin oxide and Zinc oxide is used in place of Al metal layer 52.

According to some embodiments of the present invention, capsule 100 is additionally coated with an outer layer 53 that is coated over metal layer 52. Typically, Si0₂ or SiO_x is used for outer layer 53. In some exemplary embodiments, outer layer 53 is thinner than metal layer 52. Typically, outer layer 53 is applied as a protective coating for preventing oxidation of metal layer 52. Optionally, outer layer 53 is between 50-150 nm thick, e.g. 100 nm. Optionally, capsule 100 is coated with a thicker outer layer 53, e.g. an outer layer that is approximately 200 nm thick.

Optionally, plastic material 55 is coated with a primer coating 51 prior to applying metal layer 52. Typically, primer coating 51 is used to improve subsequent adhesion of metal layer 52. Typically, silicon monoxide (SiO) is used as a primer for layer 51. Alternatively, Si0₂ is used as a primer layer 51. Optionally, primer coating 51 is excluded.

Reference is now made to FIG. 2 showing a simplified schematic perspective view of a coated capsule that is pre-perforated in accordance with some embodiments of the present invention. According to some embodiments of the present invention, capsule 200 is a plastic based capsule that is coated with a metal layer as described for example in reference to FIGS. 1A and IB and is also perforated with one or more holes 60. Optionally, while packaged, holes 60 are covered with an overlaying membrane. Typically, capsule 200 with one or more holes 60 is vulnerable to oxygen, humidity and UV radiation due to holes 60. In some exemplary embodiments, the metal coating on capsule 200 is applied to provide a polished look that may be advantageous in a marketing perspective.

Reference is now made to FIG. 3 showing a simplified flow chart of a method for manufacturing a capsule in accordance with some embodiments of the present invention. According to some embodiments of the present invention, a capsule fabricated from a plastic material is received (block 310). According to some embodiments of the present invention, a physical vapor deposition (PVD) process is used to coat the capsule with a metal layer, e.g. Al, nickel, or chrome (block 320). Typically, an evaporation technique is used in which the material of the coating is hot when applied to the capsule and the capsule material may be heated. Typically, polymer that is resistant to heat is selected as the raw material for forming the capsule and/or as the material used for the capsule body, e.g. the capsule without the coating. In some exemplary embodiments, if an additional layer, e.g. an outer layer of Si0₂ is desired (block 330), the PVD process is repeated, without taking out the capsule from the vacuum chamber. Typically, a thickness of the layer, e.g. layer 52, and/or layer 53 is defined by duration over which the PVD process is performed. Typically, thicker layers are obtained by lengthening duration of the PVD process. Optionally, the PVD process is also used for coating the capsule with a primer. Optionally, a rim of the capsule is covered during the PVD process to avoid coating the rim. According to some embodiments of the present invention, after the PVD process is completed (block 340) the coated capsules are delivered to an alternate site for filing and packaging. Alternatively, the filling and packaging can be performed on site.

It is noted that although most of the embodiments of the present invention refer to a capsule used for preparation of a hot beverage such as coffee, tea and hot chocolate, the capsule as described herein is not limited in this respect and can also be used and/or adapted for the preparation of cold beverage including carbonated beverages and/or alcoholic beverages.

It is also noted that although most of the embodiments of the present invention refer to a capsule used for preparation of a beverage, for protecting a quality of a beverage product and/or for use with a beverage machine, the capsule body as described herein is not limited for preparation of a beverage, can optionally be used for storing and/or preparing other food items and can optionally be used with other machines adapted to prepare other food products.

The terms "comprises", "comprising", "includes", "including", "having" and their conjugates mean "including but not limited to".

The term "consisting of means "including and limited to".

The term "consisting essentially of" means that the composition, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

Claims

WHAT IS CLAIMED IS:

1. A capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule including a capsule body that is formed from a polymer material that is coated with a first layer of metal and a second layer of Silicon Oxide (SiO_x).

2. The capsule of claim 1, wherein the first layer is a layer of aluminum.

3. The capsule of claim 1, wherein the first layer is selected from a group including: a layer of nickel, chrome.

4. The capsule of any one of claims 1-3, wherein the first and second layers provide a mirror finish look to the capsule.

5. The capsule of any one of claims 1-4, wherein the first layer is between 50-500 nm thick.

6. The capsule of any one of claims 1-5, wherein the second layer is between 50-150 nm thick.

7. The capsule of any one of claims 1-6, wherein the capsule includes a primer coated on polymer material and wherein the first layer is coated over the primer.

8. The capsule of claim 7, wherein the primer is silicon monoxide.

9. The capsule of any one of claims 1-8, wherein the polymer is selected from a group including: polypropylene, polyethylene, polyethylene terephthalate, amorphous polyamide, and a combination thereof.

10. The capsule of any one of claims 1-9, wherein the first and second layers are applied on the polymer material by a physical vapor deposition process.

11. A capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule being formed from a polymer material that is coated with a first layer of metal and a second layer of aluminum oxide, tin oxide, zinc oxide or a combination thereof.

12. The capsule of claim 11, wherein the second layer is a combination of silicon oxide and one or more of aluminum oxide, tin oxide and zinc oxide.

13. A capsule for use in a beverage preparation machine, the capsule adapted for containing one or more beverage ingredients, the capsule being formed from a polymer material that is coated with a layer of silicon dioxide, aluminum oxide, tin oxide and zinc oxide or a combination thereof.