Beverage

The present disclosure relates to a capsule, a beverage preparation system and a method for forming a beverage. The beverage preparation system is of the type comprising a beverage preparation machine wherein the capsule is suitable 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 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 capsule 1 having a thin aluminium cup-like body 4 and a closing foil member 2 and a beverage preparation machine having an enclosing member 9 and a capsule holder 13.

The enclosing member 9 comprises an annular element having a leading edge in the form of an annular rim 5. The leading edge may be provided with a plurality of grooves. An upper end of the enclosing member 9 may be coupled to a supply of water and also comprises one or more perforation elements 14 intended to pierce the base 17 of the capsule 1 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 , arranged along a circular path at a radius Ri from a central longitudinal axis of the enclosing member 9 so that in use the capsule 1 is intended to be perforated also at one or more points along a circular path at radius R1 from a central longitudinal axis of the capsule 1 (which in use is substantially coincident with the central longitudinal axis of the enclosing member 9).

The capsule holder 13 comprises relief elements 12 which are designed to tear and perforate the closing foil member 2 of the capsule 1. The tearing may occur due to internal pressurisation of the capsule 1 caused by inflowing water. The relief elements 12 may have any protruding shape able to cause a partial tearing of the foil member 2, e.g. pyramids, needles, bumps, cylinders, or elongated ribs.

The capsule 1 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 17 of the capsule 1 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 1 of EP 1700548 is provided with a dedicated sealing member 8 to prevent a by-pass flow of water around the exterior of the capsule in use. The sealing member 8 is in the form of a resilient material attached to a flange of the capsule which is contacted on closure of the enclosing member 9 of the beverage preparation machine.

WO2012/144885 discloses an alternative capsule for use in a system of the general type described in EP1700548. The capsule is formed with an integral sealing element for interacting with the enclosing member of the beverage preparation machine, wherein the sealing element is at least partially

manufactured from a thermoplastic polyolefin such as polypropylene.

WO201 1/061126 discloses a capsule for the preparation of a beverage.

The capsule includes a rim formed from a polymer blend selected to soften on heating. This is said to ensure a seal can be formed without the requirement for a separate rubber sealing ring. It is disclosed that the polymer may contain one or more fillers selected from calcium carbonate, titanium dioxide, fibers, glass beads and combinations thereof.

US2010/0288131 discloses a multi-laminate container for use in the preparation of a beverage, The container is formed from a polymer blend and includes calcium carbonate. This is used to scavenge free oxygen and moisture and ensure that beverage ingredients held within remain fresh and unspoiled.

It is an object of the present disclosure to address this problem, tackle the disadvantages associated with the prior art, or at least provide a commercially useful alternative thereto. A problem that can occur when using capsules formed from a polymeric material, for example polypropylene, in a system of the general type described in EP 1700548 is that the capsule may not be adequately pierced by the one or more perforation elements 14 of the beverage preparation machine. This may be due to the relative resilience to puncturing of the polymeric material compared to aluminium and/or due to relative flexibility of the base of the capsule which may lead to the one or more perforation elements 14 tending to deflect the capsule material rather than puncture it.

The present disclosure provides an alternative capsule which may be used, for example, as part of a beverage preparation system of the general type described in EP 1700548 and provides improved compatibility with the one or more perforation elements of such beverage preparation machines.

Summary of the Disclosure

In a first aspect the present disclosure provides a capsule for preparing a beverage comprising a cup-shaped body and a lid; the cup-shaped body having a base and a side wall and the lid being sealed to the cup-shaped body;

the capsule being suitable for insertion into a 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 being of the type having an enclosing member adapted to be selectively configurable 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; wherein at least a portion of the base designed to be pierced in use comprises a thermoplastic polymer, wherein said thermoplastic polymer includes silica particles.

In the following passages different aspects/embodiments are defined in more detail. Each aspect/embodiment so defined may be combined with any other aspect/embodiment or aspects/embodiments unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous.

By forming at least the portion of the base designed to be pierced in use to comprise a thermoplastic polymer containing silica particles an improved perforation of the base may be promoted. In particular, whilst not wishing to be bound by theory, the behaviour of the portion of the base designed to be pierced in use under loading is understood to be modified by reducing the degree of, or eliminating, plastic yielding prior to fracture of the material. This promotes the formation of larger perforations in the base under the loading of the one or more perforation elements 14 of the beverage preparation machine compared to a thermoplastic polymer without the silica particles. In addition, the nature of the perforations tends to be changed from holes that approximately match the shape of the intruding perforation element (e.g. a round hole produced by a round needle) to slits or openings which propagate further away from the point of contact of the perforation element.

The larger perforations may be beneficial in promoting easier admittance of water into the capsule in use.

The silica particles preferably have a particle size D50 of from 5 to 330 microns, more preferably from 10 to 150 microns, and in one example from 10 to 15 microns. In a further example the particle size D50 may be from 110 to 120 microns. Techniques for measuring particles sizes are well known in the art. Preferably the measurements are taken with laser diffraction, such as the method described in ISO 13320-1. It should be appreciated that one method of forming the silica particles is by a precipitation method and it is known that this can be controlled to arrive at the desired particle size ranges.

Preferably the silica particles have a specific surface area of at least 150 m ² /g, preferably of at least 170 m ² /g. Specific surface area measurements are well known in the art. Such high surface areas are not observed for some conventional fillers such as fibers or glass beads.

Advantageously, it has been found that both hydroscopic and hydrophobic silica particles provide the same functionality of improving the perforation of the base. The thermoplastic polymer of at least the base designed to be pierced preferably includes at least 5% by weight silica particles. Preferably the silica particles are present in an amount of from 10% to 30% by weight in the thermoplastic polymer, more preferably from 13% to 15% by weight silica

5 particles. When the level of silica particles is too low, the advantageous

pierceability of the base is not observed, whereas when the level is too high, the injection moulding process is adversely affected.

The silica particles used in the present disclosure are formed of silicon and oxygen and will typically be SiO ₂ , together with any unavoidable impurities. In l o another embodiment, the silica particles consist essentially of SiO ₂ . The silica particles preferably comprise substantially pure SiO ₂ . For example, the silica particles may be at least 90% by weight SiO ₂ , preferably at least 95% by weight SiO ₂ , more preferably at least 97% by weight SiO _2| measured following ISO 3262-19 based on ignited substance (2h/1000°C).

15 Conventional glass beads provide little or no free silica. In contrast, the preferred silica particles used in the present disclosure are capable of providing free silica.

The silica particles may comprise precipitated silica particles. These may be produced by known precipitation techniques, for example from a solution

20 containing silicate salts. In more detail, it is known to prepare precipitated silica by reacting an acidifying agent (for example sulphuric acid, nitric acid or hydrochloric acid) with a silicate of an alkali metal (for example sodium silicate or potassium silicate) to obtain a suspension of precipitated silica. The suspended precipitated silica is then separated and dried to produce a powder of precipitated

25 silica. Precipitated silica particles produced by such processes are generally amorphous in structure and also porous. An example of a preferred precipitated silica is one having one or more of the following characteristics: specific surface area (N ₂ ) of 100 to 600 m ² /g, measured by ISO 9277; and/or particle size D50 of 5 to 330 microns, measured by ISO 13320-1. As already noted, the precipitated

30 silica particles may be SiO ₂₎ together with any unavoidable impurities, or may consist essentially of SiO ₂ (preferably may be at least 90% by weight SiO ₂ , preferably at least 95% by weight SiO ₂ , more preferably at least 97% by weight SiO ₂ , measured following ISO 3262-19 based on ignited substance (2h/1000°C).)

A whole of the base may comprise the thermoplastic polymer containing the silica particles.

Without wishing to be bound by theory, it is considered that the inclusion of the silica particles provides an optimum material for forming the cup-shaped body. In particular, silica particles are sufficiently fine to be readily distributed within the thermoplastic polymer, and have a high specific surface area which allows them to form an integral part of the final polymer. It is considered that this allows the material to rip when pierced and, therefore, allows the provision of a larger hole. Nonetheless, the silica particles do not interfere with the softening of the polymer which may be desirable to allow a good seal to be achieved of a flange. Advantageously, the silica particles can be readily mixed and then injection moulded to form the cup-shaped body. This provides a simple cost- effective one-step method for the formation of the capsule.

A central region of the base within the portion of the base designed to be pierced in use may comprise a in the form of a circumferentially-arranged series of corrugations.

The circumferentially-arranged series of corrugations may have a constant wall thickness.

Each corrugation of the series of corrugations may be radially-orientated.

In a second aspect, the present disclosure provides a capsule for preparing a beverage comprising a cup-shaped body and a lid; the cup-shaped body having a base and a side wall and the lid being sealed to the cup-shaped body;

the capsule being suitable for insertion into a 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 being of the type having an enclosing member adapted to be selectively configurable 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; at least a portion of the base designed to be pierced in use comprises a thermoplastic polymer;

wherein the base and the side wall have a constant thickness.

The portion of the base designed to be pierced in use may be free of reinforcement members.

A central region of the base within the portion of the base designed to be pierced in use may comprise a in the form of a circumferentially-arranged series of corrugations.

The circumferentially-arranged series of corrugations may have a constant wall thickness.

Each corrugation of the series of corrugations may be radially-orientated. In a third aspect, the present disclosure provides a capsule for preparing a beverage comprising a cup-shaped body and a lid; the cup-shaped body having a base and a side wall and the lid being sealed to the cup-shaped body;

the capsule being suitable for insertion into a 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 being of the type having an enclosing member adapted to be selectively configurable 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; at least a portion of the base designed to be pierced in use comprising a thermoplastic polymer;

wherein a central region of the base within the portion of the base designed to be pierced in use comprises a structure in the form of a

circumferentially-arranged series of corrugations.

The circumferentially-arranged series of corrugations may have a constant wall thickness.

Each corrugation of the series of corrugations may be radially-orientated. The above aspects may further comprise one or more of the following features, singly or in combination: The at least a portion of the base designed to be pierced in use may be formed from a single layer of the thermoplastic polymer containing silica particles. Preferably, a whole of the cup-shaped body is formed from the thermoplastic polymer, more preferably from a single layer of the thermoplastic polymer.

Alternatively, the at least a portion of the base designed to be pierced in use may comprise a laminate, the laminate comprising at least one layer of the thermoplastic polymer containing silica particles. Preferably, a whole of the cup- shaped body is formed from a laminate the laminate comprising at least one layer of the thermoplastic polymer containing silica particles. The laminate may comprise a barrier layer, for example of EVOH. The barrier layer may comprise an internal layer of the laminate which is sandwiched between one or more inner layers of thermoplastic polymer and one or more outer layers of thermoplastic polymer. Either or both of the one or more inner layers and the one or more outer layers may contain silica particles.

The thermoplastic polymer may comprise a polyethylene and/or

polypropylene polymer or co-polymer.

In one example, the thermoplastic polymer comprises a high density polyethylene polymer.

In another example, the thermoplastic polymer comprises a low density polyethylene polymer, preferably a linear low density polyethylene polymer (LLDPE).

Alternative thermoplastic polymers that may be used include

polypropylene, ABS, polystyrene and blends of any of the preceding polymers.

Preferably the thermoplastic polymer consists of the polymer and the silica particles. Accordingly, preferably in one example the base to be pierced consists of high density polyethylene polymer and silica particles. In another example, preferably the base to be pierced consists of low density polyethylene and silica particles. As will be appreciated, there may be unavoidable impurities present in the thermoplastic polymer. However, preferably these will form less than 1wt% of the polymer, more preferably less than 0.1 wt% thereof.

A whole of the cup-shaped body may be formed as a single injection moulding. This may have the advantage of allowing fast and cost-efficient manufacture of the capsules.

Preferably the concentration by weight of silica particles in the thermoplastic polymer is substantially constant. Thus, if the thermoplastic polymer includes 20% by weight of the silica particles, then this concentration of 20% by weight is substantially constant throughout, for example, the cup-shaped0 body.

Alternatively, the concentration by weight of silica particles in the thermoplastic polymer may be greater in the portion of the base designed to be pierced in use than in the rest of the cup-shaped body. That is, the concentration in the portion of the base designed to be pierced in use may be 20% by weight,5 whereas the remainder of the cup-shaped body may have, for example, less or substantially no silica particles. In one embodiment, the concentration by weight of silica particles in the thermoplastic polymer may decrease across the cup- shaped body away from the portion of the base designed to be pierced in use. This decrease may be linear and or variable. For example, the ratio of the o concentration by weight of silica particles in the portion of the base designed to be pierced in use to the concentration by weight of silica particles in a flange or the outer limit of the cup-shaped body may be at least 2:1 , and preferably up to from 10:1.

The portion of the base designed to be pierced in use may have a wall 5 thickness in the range of 0.30 to 0.50 mm.

The base and the side wall may have a constant thickness.

The portion of the base designed to be pierced in use may be free of reinforcement members. This may facilitate easier and more consistent perforation of the base by the one or more perforation elements since the o presence of reinforcement members crossing the portion of the base designed to be pierced in use can impede the movement of the perforation elements leading to potentially a sub-optimum sized perforation being formed in the base. The cup-shaped body may further comprise a flange at an end of the side wall opposite the base.

The flange may comprise a sealing element located on an upper side of the flange. The sealing element may be intended for facilitating the production of a fluid-tight engagement of the capsule with the enclosing member in use.

The sealing element may comprise a portion having a substantially triangular cross-section with two sides that extend from the upper side of the flange.

An outer of the two sides of the sealing element may comprise a straight0 side and an inner of the two sides may comprise a side having a straight portion distal an apex of the sealing element and a convex upper portion proximate the apex of the sealing element. This design is advantageous in being compatible with venting apertures in the mould tools.

The flange may further comprise a cavity on a lower side of the flange

5 and/or a peripheral portion that is directed downwards. The cavity may improve the mouldability of the capsule flange.

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 o optionally comprise one or more lines or points of pre-weakness to promote

tearing in use. Alternatively, the lid may comprises one or more pre-formed openings so as to act as a filter irrespective of whether the lid is further torn or punctured in use by the beverage preparation machine.

In one example the side wall may comprise, on an inside thereof, a

5 plurality of longitudinal ribs which may be circumferentially-arranged and which extend at least partially between the base and the lid. The longitudinal ribs may comprise a first section, proximate the base, and a second section, proximate the lid, wherein the second section of the longitudinal ribs is shallower than the first section. The first section of the longitudinal ribs may extend inwardly from the o side wall by a distance from 1.5 to 2.0 mm. The second section of the longitudinal ribs may extend inwardly from the side wall by a distance of no more than 0.25 mm. The longitudinal ribs may serve to strengthen the capsule to resist loadings applied in use by the enclosing member and/or hydraulic pressures.

In another example, the side wall may be designed with a corrugated form. The corrugated form may comprise a plurality of longitudinally-orientated corrugations. Each corrugation may extend over a majority of the height of the side wall. Again, the corrugated form may serve to strengthen the capsule.

Prior to insertion, the capsule may have a maximum diameter of from 35 to 38 mm, preferably 37 mm.

Prior to insertion, the capsule may have a height of from 25 to 31 mm, preferably between 27 and 28 mm.

The capsule may form a single-use, disposable element.

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

The present disclosure also provides a beverage producing system comprising:

a capsule as described in any of the aspects above and containing beverage ingredients; and

a beverage preparation machine;

the beverage preparation machine having an enclosing member adapted to be selectively configurable 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 beverage preparation machine further comprising one or more perforation elements which in use perforate the base of the capsule to permit entry of liquid into the capsule.

The present disclosure also provides a method for preparing a beverage comprising the steps of:

- providing a capsule as described in any of the aspects above;

- providing a beverage preparation machine having an enclosing member; - configuring the enclosing member into an open position;

- inserting the capsule into the beverage preparation machine;

- closing the enclosing member so as to sealingly engage the enclosing member with the capsule;

- during or after closure of the enclosing member forming one or more perforations in the base of the capsule;

- flowing a pressurised liquid into the one or more perforations and through the capsule to produce a beverage from interaction with the beverage

ingredients; and

- outputting the beverage for consumption.

Forming the one or more perforations in the base of the capsule may comprise forming one or more slits in the base of the capsule.

The one or more slits may be orientated radially.

The one or more slits may have a length substantially greater than their width.

The present disclosure provides a method of forming the capsule as described herein, the method comprising:

providing a molten blend of a thermoplastic polymer and silica particles; and

injection moulding the blend to form the capsule.

The injection moulding may comprise co-injection moulding into a mould the molten blend of the thermoplastic polymer and silica particles for forming an inner layer and an outer layer of the cup-shaped body and co-injecting a second material, chosen for its barrier properties, into the same mould to form an internal layer of the cup-shaped body. For example, an EVOH barrier layer may be co- injected. An adhesive component may be blended with the thermoplastic polymer to promote adhesion of the inner layer and the outer layer to the internal (ayer. For example, an adhesive resin may be used. In one example an anhydride- modified thermoplastic resin, for example, anhydride-modified PP may be used.

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 perspective view from above of a first embodiment of capsule according to the present disclosure;

Figure 3 is a side view of the capsule of Figure 2;

Figure 4 is a cross-sectional view through the capsule of Figure 2;

Figure 5 is a perspective view from below of the capsule of Figure 2 with the lid removed for clarity;

Figure 6 is an enlarged view of a portion of Figure 5;

Figure 7 is an enlarged view of a portion of Figure 4;

Figure 8 is an enlarged view of a portion of Figure 2;

Figure 9 is an enlarged view of a portion of Figure 4;

Figure 10 is a cross-sectional view of the capsule of Figure 2 in a beverage preparation machine;

Figures 11a and 11b are photographs showing the inside of a base of a capsule according to the design of Figure 2 and formed from a first material after perforation by a beverage preparation machine;

Figures 12a and 12b are photographs showing the inside of a base of a capsule according to the design of Figure 2 and formed from a second material after perforation by a beverage preparation machine;

Figure 13 is a perspective view from above of a second embodiment of capsule according to the present disclosure;

Figure 14 is a cross-sectional view through the capsule of Figure 13;

Figure 15 is a perspective view from below of the capsule of Figure 13 with the lid removed for clarity;

Figure 16 is a schematic perspective view of a perforation element from a prior art Nespresso® U beverage preparation machine and Figure 17 is a graph of force against displacement during testing of piercing of two types of capsules;

Figures 18a and 18b are photographs showing the inside of a base of a capsule according to the design of Figure 2 and formed from a third material after 5 perforation by a beverage preparation machine;

Figures 19a and 19b are photographs showing the inside of a base of a capsule according to the design of Figure 2 and formed from the second material after perforation by a beverage preparation machine;

Figure 20 is a cross-sectional view through a modified version of the

0 capsule of Figure 2;

Figure 21 is an enlarged view of a portion of Figure 20; and

Figure 22 is an enlarged view of another portion of Figure 20.

Detailed Description

5 Figure 2 illustrates a first embodiment of capsule 20 according to the

present disclosure which may be used with a beverage preparation machine to produce a beverage. The capsule 20 and the beverage preparation machine together define a beverage preparation system.

The capsules of the present disclosure may be used, for example, with a o 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.

5 The enclosing member 9 and the capsule holder 13 in the closed position together define a receptacle 30 for holding the capsule 20 during a dispensing operation.

In addition, the beverage preparation machine may comprise conventional elements which are not illustrated in the accompanying drawings and which are o 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 capsule 20. 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.

As shown in Figures 2 to 4, the capsule 20 comprises a cup-shaped body 21 and a lid 22. The cup-shaped body 21 has a base 23 at one end of the cup- shaped body 21 and a side wall 24 which extends from base 23 and terminates at an open end 25 which may be closed off in use by the lid 22.

The cup-shaped body 21 and the lid 22 together enclose a beverage ingredient chamber 29 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 side wall 24 may have a generally frusto-conical form with a basal end of the side wall 24 having a smaller diameter than the open end 25.

The base 23 may have a generally convex dome-shaped form as viewed from the exterior of the capsule.

The transition between the side wall 24 and the base 23 may be marked by a step change in diameter with the base 23 having a smaller diameter than the side wall 24. As shown in Figure 4, this may lead to a basal end of the side wall 24 defining an outward-extending shoulder 50. The outward-extending shoulder 50 may be convex in form as viewed from the exterior of the capsule.

The side wall 24 may be provided with decorative embossing. As an example, the decorative embossing may comprise a pictorial representation of coffee beans 51 and a circumferential array of shallow undulations 52.

The base 23 may define an inlet end of the capsule 20 and the lid 22 may define an outlet end of the capsule 20.

The capsule 20 may further be provided with a flange 26 at the open end 25. The flange 26 may extend outwardly from the side wall 24 and define an upper side 27 and a lower side 28. A bottom of the flange 26 may define an end face 61 of the cup-shaped body 21 , as most clearly seen in Figure 7. As shown in Figure 7, a sealing element 40 may be provided on the upper side 27 of the flange 26. The sealing element 40 may comprise a portion 41 having a substantially triangular cross-section with two sides that extend from the upper side 27 of the flange 26. An outer side 42 of the sealing element 40 may have a straight side. An inner side 43 may have a straight portion 44 distal an apex 46 of the sealing element 40 and a convex upper portion 45 proximate the apex 46 of the sealing element 40.

The sealing element 40 may be spaced from the side wall 24 so as to define a gulley 49 there between. The apex 46 may be distanced radially 1.0 mm from the side wall 24.

The gulley 49 may have a gulley floor 60 at a first height above the end face 61 of the capsule 20 at the open end 25. The thickness of the flange 26 in line with the gulley 49 may be 0.62 mm.

The apex 46 of the sealing element 40 may rise above the gulley floor 60 to a second height above the end face 61. The height of the apex 46 may be 0.70 mm higher than the height of the gulley floor 60 and 1.32 mm above the end face 61.

The flange may comprise a peripheral portion 63 lying outside the sealing element 40 at a third height above the end face 61. The third height may be greater than the first height but less than the second height. The third height may be 0.98 mm. The peripheral portion 63 may extend outwardly substantially parallel to the end face 61 and terminate with an edge region 64 that is directed downwards away from the base 23.

The lower side 28 of the flange 26 may comprise a cavity 47 underneath· the peripheral portion 63 of the flange 26.

As shown in Figures 2, 8 and 9, the base 23 may comprise an annular region 70 including a portion of the base 23 which is designed to be pierced in use by the one or more perforation elements of the beverage preparation machine. The annular region 70 may be substantially frusto-conical in shape. The annular region 70 may be smooth and thin-walled and, in particular may be free of reinforcement members. The annular region 70 may have a wall thickness in the range of 0.30 to 0.50 mm. Outside the annular region 70, the base 23 may comprise a peripheral region 71 which is convexly-shaped when viewed from the exterior of the capsule 1. The peripheral region 71 may be immediately adjacent the outward-extending shoulder 50 of the side wall 24. The peripheral region 71 may have a wall

5 thickness in the range of 0.30 to 0.50 mm.

Inside the annular region 70, the base 23 may comprise a central region 72 which comprises a structure in the form of a circumferentially-arranged series of corrugations 75, as best seen in Figures 8 and 9. The circumferentially- arranged series of corrugations 75 is provided with complementary shaping on0 the inner and outer surfaces of the base 23 such that the reinforcing structure has a constant, or substantially constant, wall thickness. The wall thickness may be in the range of 0.30 to 0.50 mm. Thus, the wall thickness is preferably the same wall thickness as the rest of the base 23 and side wall 24.

Each corrugation of the series of corrugations may be radially-orientated5 so as to emanate from a central point 73 of the base 23. A gate recess 78 to

facilitate the moulding process, may be provided at the central point 73. An inner circumferential rib 77 may be provided to demarcate the gate recess from the corrugations 75. Similarly, an outer circumferential rib 76 may be provided to demarcate the corrugations 75 from the annular region 70. An outer edge of the o outer circumferential rib 76 may be level with the outer surface of the annular region as shown in Figure 9 such that the reinforcing structure 74 does not protrude from the base 23.

As shown in Figures 4 to 7, the side wall 24 may be thin walled. The side wall 24 may have a wall thickness in the range of 0.30 to 0.50 mm.

5 The side wall 24 may comprise, on an inside thereof, a plurality of

longitudinal ribs 80 which may be circumferentially-arranged and which may extend at least partially between the base 23 and the lid 22. A total of 20 longitudinal ribs 80 are provided in the illustrated example.

The longitudinal ribs 80 may comprise a first section 81 , proximate the o base 23, and a second section 82, proximate the lid 22, wherein the second

section 82 of the longitudinal ribs 80 is shallower than the first section 81. The first section 81 of the longitudinal ribs 80 may extend inwardly from the side wall 24 by a distance from 1.5 to 2.0 mm. The second section 82 of the longitudinal ribs 80 may extend inwardly from the side wall by a distance of no more than 0.25 mm. The second section 82 may extend from the end face 61 of the cup- shaped body 21 for up to 5 mm along the length of the capsule 20.

The reduced depth of the longitudinal ribs 80 in the second section 82 near the lid 22 is to avoid obstruction of the filling and tamping tools. In particular, the filling operation may use a rotating auger and the tamping may utilise a tamper which is twisted within the confines of the capsule so as to promote easier detachment of the tamper from the tamped beverage ingredient. The reduced depth of the longitudinal ribs 80 in the second section 82 prevents contact between the longitudinal ribs 80 and the tools.

In addition to the longitudinal ribs 80, supplementary ribs 83 may be provided interposed between the longitudinal ribs 80 and which extend for only a short distance of up to 5 mm from the end face 61 towards the base 23. These can be beneficial is providing extra reinforcement to the side wall 24 of the capsule 20 near the flange 26.

The lid 22 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.

In the illustrated example, at least the annular region 70 of the base 23 comprises a thermoplastic polymer containing silica particles.

In one example, at least the annular region 70 may be formed of just the thermoplastic polymer containing the silica particles (e.g. one layer of material) and preferably the whole of the base 23 may be formed of the thermoplastic polymer containing silica particles. In such a case, more preferably a whole of the cup-shaped body 21 may be formed of a single material, i.e. the thermoplastic polymer containing silica particles.

Alternatively, in another example, at least the annular region 70 may be formed of a laminate of two or more layers. Preferably the whole of the base 23 may be formed of the laminate. In such a case, more preferably a whole of the cup-shaped body 21 may be formed of the laminate. In each case, the laminate will comprise at least one layer of the thermoplastic polymer containing silica particles. The laminate may comprise two or more layers of different

thermoplastic polymers one or all of which may contain the silica particles.

The laminate may comprise a barrier layer, for example of ethylene vinyl alcohol (EVOH), for example Soarnol DC3212B available from Soarus LLC of Arlington Heights, USA. The barrier layer may comprise an internal layer of the laminate which is sandwiched between one or more inner layers of thermoplastic polymer and one or more outer layers of thermoplastic polymer. Either or both of the one or more inner layers and the one or more outer layers may contain the silica particles.

The silica particles may have a particle size D50 as measured by laser diffraction in accordance with ISO 13320-1 in the range of 5 to 330 microns.

In one example, the silica particles may have a particle size D50 in the range of 10 to 150 microns. In other examples the silica particles may have a particle size D50 in the range of 10 to 15 microns or 1 10 to 120 microns.

The silica particles may comprise substantially pure S1O2. The silica particles may be in the form of precipitated silica.

A non-limiting example of suitable silica particles is the precipitated silica Sipernat® 22 manufactured by Evonik Industries AG of Hanau, Germany. Other examples, also manufactured by Evonik Industries AG of Hanau, Germany, include Sipernat® 22 S, Sipernat® D 17, Sipernat® 609, Sipernat® 2200,

Sipernat® 680 and Sipernat® 303.

The thermoplastic polymer for use with the silica particles may comprise a polyethylene and/or polypropylene polymer or co-polymer. The thermoplastic polymer may comprise a blend of thermoplastic polymers.

In one example the thermoplastic polymer may comprise a high density polyethylene polymer (HDPE).

A non-limiting example of a suitable thermoplastic polymer is Eraclene MS 80 U HDPE manufactured by Polimeri Europa S.p.A. of Milan, Italy.

In another example the thermoplastic polymer may comprise a low density polyethylene polymer, for example a linear low density polyethylene (LLDPE). A non-limiting example of a suitable thermoplastic polymer is M500026 LLDPE manufactured by Saudi Basic Industries Corporation (SAB1C) of Riyadh, Saudi Arabia.

In one example, the laminate comprises an outer layer of thermoplastic polymer, an internal barrier layer of EVOH and an inner layer of thermoplastic polymer. As noted above, the thermoplastic polymer may comprise a blend of the HDPE and the LLDPE and contain the silica particles throughout. In one example the thermoplastic polymer blend comprises 50% by weight LLDPE, 37% by weight HDPE and 13% by weight silica particles. This blend may be used for both0 the inner and outer layers of the above example. The thermoplastic polymer

blend may also, optionally, comprise an adhesive component to promote bonding of the thermoplastic polymer blend to the EVOH barrier layer. For example, an anhydride-modified thermoplastic may be used. One example is Bynel 50E806 anhydride-modified polypropylene available from Du Pont of Wilmington,

5 Delaware, USA. An amount of 3% to 5% by weight of the adhesive component is preferably incorporated into the LLDPE/HDPE/Silica blend. For example, the blend may be 45% by weight LLDPE, 32% by weight HDPE , 5% by weight Bynel 50E806 PP, 5% by weight EVOH and 13% by weight Silica particles. Optionally, the blend may also include a Masterbatch colouring component.

o The thermoplastic polymer may comprise greater than 5% by weight silica particles. Preferably the thermoplastic polymer comprises from 10% to 30% by weight silica particles. More preferably the thermoplastic polymer comprises 13- 15% by weight silica particles.

The thermoplastic polymer may be compounded by heating in a suitable 5 vessel, for example a barrel, and adding the silica particles in one or more

portions as the base thermoplastic polymer passes along the heated vessel. The thermoplastic polymer is then extruded and pelletised.

The cup-shaped body 21 may be formed by injection moulding. A whole of the cup-shaped body 21 may be formed as a single injection moulding. This o allows for simpler and more rapid manufacture.

Where the cup-shaped body 21 comprises a laminate structure, for example, thermoplastic polymer - EVOH barrier layer - thermoplastic polymer, the cup-shaped body 21 may be formed by co-injection moulding wherein a first material for forming the inner and outer layers of the laminate is injected into the mould at the same time as injecting a second material, chosen for its barrier properties, into the same mould to form the internal (middle) layer of the laminate.

Figures 20 to 22 illustrate a modified version of the capsule of Figure 2 which incorporates an EVOH barrier layer 90. As can be seen the barrier layer 90 extends from at or near the central point 73 near the gate recess 78 to within the flange 26 where the barrier layer 90 preferably extends beyond the point of the apex 46 of the sealing element 40. Figure 10 shows the capsule 20 being used in the beverage preparation machine. The enclosing member 9 is first moved into the open position and the capsule 20 is inserted into a location in between the capsule holder 13 and the enclosing member 9. The enclosing member 9 is then closed so as to sealingly engage the enclosing member 9 with the capsule 20. A fluid-tight seal between the annular rim 5 of the enclosing member 9 and the flange 26 of the capsule 20 is formed. In particular, the annular rim 5 of the enclosing member 9 is at least partially received in the gulley 49 and contacts and seals against the inner side 43 of the sealing element 40 and/or the gulley floor 60.

During closure of the enclosing member, the base 23 of the capsule 20 is perforated by the one or more perforation elements 14 of the enclosing member 9.

Water is then flowed into the capsule 20 to produce a beverage from interaction with the beverage ingredients. During this step internal pressurisation of the beverage ingredient chamber 29 causes the lid 22 to be deformed outwardly against the relief elements 12 of the capsule holder 3 resulting in at least partial tearing of the lid 22 which opens up an exit path from the capsule 20 for the beverage.

The beverage is then output for consumption.

According to the present disclosure, by forming at least the annular region 70 of the base 23 to comprise a thermoplastic polymer containing silica particles an improved perforation of the base 23 is promoted. In particular, whilst not wishing to be bound by theory the behaviour of the annular region 70 under loading is understood to be modified by reducing the degree of, or eliminating, plastic yielding prior to fracture of the thermoplastic material. This results in the formation of larger perforations in the base 23 under the loading of the one or more perforation elements 14 of the beverage preparation machine compared to the thermoplastic polymer without silica particles. In addition, the nature of the perforations tends to be changed from holes that approximately match the shape of the intruding perforation element (e.g. a round hole produced by a round needle) to slits or openings which propagate further away from the point of contact of the perforation element.

The larger perforations are beneficial in promoting easier admittance of water into the capsule 20 in use.

Example

Sample 1 : a capsule 20 according the design of Figure 2 was formed of a single layer of a first material:

Eraclene MS 80 U HDPE 97% by weight

Masterbatch colouring 3% by weight.

The capsule 20 was then inserted and used in a Nespresso® U beverage preparation machine having a design of perforation element as shown in Figure 16.

Figure 11a illustrated the perforations formed in the base 23 by the three perforation elements of the beverage preparation machine. Figure 11b is an enlarged view of one of the perforations.

As can be seen the piercing performance was poor with little or no piercing apparent. The open area of each perforation formed was approximately 0.06 mm ² .

Sample 2: a capsule 20 according the design of Figure 2 was formed of a single layer of a second material:

Eraclene MS 80 U HDPE 77% by weight Sipernat® 22 silica 20% by weight

Masterbatch colouring 3% by weight.

The capsule 20 was then inserted and used in the same Nespresso® U beverage preparation machine as Sample 1.

Figure 12a illustrated the perforations formed in the base 23 by the three perforation elements of the beverage preparation machine. Figure 12b is an enlarged view of one of the perforations.

As can be seen the piercing performance was greatly improved with the formation of three large slit-shaped apertures. The open area of each perforation formed was approximately 0.76 mm ² .

It has been found that the use of silica particles in the thermoplastic polymer provides an improved capsule performance when pierced compared to the use of glass beads. Figure 17 shows a graph of force against displacement during piercing of two types of capsules of the shape and design shown in Figure 2, but formed of different materials. In a first sample the capsules were formed of a material consisting of Eraclene MS 80 U HDPE 87% by weight, Sipernat® 22 silica 10% by weight and Masterbatch colouring 3% by weight. For comparison a second sample was formed of a material consisting of Eraclene MS 80 U HDPE 87% by weight, ΪΜ30Κ Hi-Strength Glass Bubbles (available from 3M Belgium N.V.) 10% by weight and Masterbatch colouring 3% by weight.

The samples were tested on an Extensometer in order to record how much force was required to pierce the capsule using a perforation element of the type shown in Figure 16. As can be seen from Figure 17, the force versus displacement for the second sample containing the glass beads shows no sign of yielding/piercing of the capsule and the trace is roughly linear. This can also be seen in Figures 18a and 18b which illustrate that the perforation element failed to form a through aperture even up to a load of over 60N.

By contrast, the first sample containing the silica particles shows a clear point of yielding at a loading of approximately 45N. The clear perforation performance can also be seen in Figures 19a and 19b' which illustrate that large split-type fractures have been formed. Figures 13 to 15 illustrate a second embodiment of capsule 120 according to the present disclosure which may be used with a beverage preparation machine to produce a beverage. In the following only the differences between the capsule 120 and the capsule 20 will be discussed and like components have been referenced using like numbers. In other respects the details of the capsules are the same. In particular, the design of the base 123, flange 126 and lid 122 and the materials of the capsule 120 are the same as for the capsule 20 described above. For example, the cup-shaped body 121 may be formed from a single layer of thermoplastic polymer containing silica particles or a laminate material as described above.

The side wall 124 of the capsule 120 differs from the first embodiment. In particular, the side wall 124 is designed with a corrugated form. The corrugated form comprises a plurality of corrugations 200 which may be longitudinally- orientated and which may extend over a majority of the height of the side wall 124. The corrugations 200 may extend from the outwardly-extending shoulder 150 to a point a little above the end face 161 of the cup-shaped body 12 . For example the corrugations 200 may stop up to 5 mm away from the end face 161. This gap near the lid 122 is to avoid obstructing entry of a tamping tool into the open end 125 of the capsule 120 after filling of the capsule with beverage ingredient.

The side wall 124 may have a wall thickness in the range of 0.30 to 0.50 mm.

Although preferred embodiments of the disclosure have been described herein in detail, it will be understood by those skilled in the art that variations may be made thereto without departing from the scope of the disclosure or of the appended claims.