Note: Descriptions are shown in the official language in which they were submitted.
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CAPSULE FOR MAKING BEVERAGES
DESCRIPTION
This invention relates to a capsule for making beverages. In particular
reference
is made to those capsules comprising an outer body and a lid which closes the
top of the outer body and in which a powdered food substance (for example
coffee powder) is positioned, which can be extracted by passing water (which
may be pressurised) through it to make a beverage, for example coffee. More
specifically reference is made to those capsules in which the outer body
comprises a lower wall and a side wall which form a chamber in which a rigid
or semi-rigid filtering body is positioned.
In more detail, reference is made to those capsules suitable for use in
beverage
making systems in which the capsule is pierced at the lid, to allow the
injection
of water (which may be pressurised) into the capsule itself, and at the lower
wall,
to allow dispensing outside the capsule of the beverage produced by the
interaction of the water with the powdered food substance.
In such capsules the filtering body is substantially a flat filtering body,
normally
disk-shaped, positioned close to the lower wall of the capsule outer body and
separates the powdered food substance from the lower wall in such a way that
powder does not come out of the capsule after a piercing element has
penetrated
through the lower wall. In fact, the filtering body on one hand allows the
beverage
to pass through it in such a way that said beverage can come out of the
capsule
through the lower wall (through a hole made by the piercing element or through
a
channel present in the latter), and on the other hand allows the powdered food
substance to be retained inside the capsule.
However, this prior art technology may have several disadvantages under
certain
circumstances.
In particular, with some types and particle sizes of the powdered food
substance, and when dispensing relatively large quantities of beverage (such
as
American coffee), the prior art capsules may not allow optimum extraction of
the
powdered food substance. In fact, for example, the beverage made by the
interaction between the water and the powder located close to the lid, in
order to
be able to come out of the capsule must reach the filtering body and therefore
2
must pass through all of the powder below which may obstruct its path. In
fact,
once moistened with the water, the powdered food substance tends to become
compacted, obstructing the flow of the liquids which encounter increased
resistance to permeation through the powder.
In fact, the water injected into the capsule tends to cause compacting of the
powdered food substance at the filtering body, therefore increasing the
resistance of the powdered food substance to the passage of liquids through it
and resulting in difficulties draining the beverage through it.
Moreover, during the injection of water into the capsule, areas are created in
the
powder which are compacted to different degrees. Therefore, prior art capsules
have the disadvantage that the powdered food substance can only be permeated
unevenly, that is to say, to drastically different degrees depending on the
position of
the powdered food substance in the capsule. Moreover, in prior art capsules,
since
the water tends to flow in the zones of the powder which are less resistant to
permeation, preferential channels for the passage of the water are easily
created,
the result being that the powdered food substance is not all permeated
homogeneously.
A first solution which overcomes such disadvantages is described in Italian
patent
application No. VR2012A000133 and in the corresponding US patent application
No. 13/549,904 (granted as U.S. 9,079,705) by this Applicant, whose content
had
still not been disclosed at the time this patent application was filed.
In this case, the disk-shaped filter was replaced by a basket-shaped rigid or
semi-
rigid filter having openings in its side wall, which is distanced from the
inner part
of the side wall of the outer body. Thanks to this solution it was practically
possible to avoid the various clogging problems which in contrast may occur
with prior art capsules.
However, even this solution did not allow all possible disadvantages to be
overcome.
In particular, when the powdered substance is milled in a way that is not
suitable and contains too much powder which is below a predetermined particle
size, it is possible that powder will come out with the beverage, with a
consequent
deterioration of the quality of the beverage (even if, as is known, an
extremely
small quantity of powder coming out is substantially normal when preparing
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beverages of this type, particularly coffee).
Finally, there are also some prior art capsules in which in place of a flat
rigid or
semi-rigid filter, , there is a conical or frusto-conical filter formed by a
layer of
flexible material. However, even these capsules have significant
disadvantages.
In particular, if relatively large quantities of beverage are dispensed, such
as
American coffee, when the powder gets wet it tends to become compacted on
the bottom of the filter, clogging it. At that point the extraction water a
can no
longer penetrate the powder and tends to bypass it, coming out of the filter
laterally, above the powder, therefore without any extraction taking place.
The
resulting beverage is therefore of poor quality.
In this context, the technical purpose which forms the basis of this invention
is to
provide a capsule for making beverages which overcomes the above-mentioned
disadvantages.
In particular, it is the technical purpose of this invention to provide a
capsule for
making beverages which allows the water entering to permeate the powdered
food substance more evenly than prior art capsules, at the same time
minimising
the risk of powder coming out with the beverage.
It is also the technical purpose of this invention to provide a capsule for
making
beverages which allows limitation, compared with prior art capsules, of the
risk
of forming highly compacted zones, in the powdered food substance, which
could obstruct the flow of the beverage, and or of preferential water passage
channels.
The technical purpose specified and the aims indicated are substantially
achieved
by a capsule for making beverages as described in the appended claims.
Further features and the advantages of this invention are more apparent in the
detailed description below, with reference to several preferred, non-limiting
embodiments of a capsule for making beverages, illustrated in the accompanying
drawings, in which:
- Figure 1 is a schematic axonometric exploded view of a capsule made in
accordance with a first embodiment of this invention, in cross-section along a
vertical middle plane;
- Figure 2 is a schematic axonometric exploded view of a capsule made
in accordance with a second embodiment of this invention, in cross-section
along
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a vertical middle plane;
- Figure 3 is
a schematic vertical middle cross-section of a capsule made in
accordance with a third embodiment of this invention, similar to the first
embodiment; it should be noticed that for greater clarity Figure 3 only shows
the
details visible in the cross-section plane and not those in the background;
- Figure 4 is
a schematic vertical middle cross-section of a capsule made in
accordance with a fourth embodiment of this invention, similar to the second
embodiment; it should be noticed that for greater clarity Figure 4 only shows
the
details visible in the cross-section plane and not those in the background;
- Figure 5 is
a schematic vertical middle cross-section of a capsule made in
accordance with a fifth embodiment of this invention; it should be noticed
that
Figure 5 also only shows the details visible in the cross-section plane and
not
those in the background;
- Figure 6 is
a schematic vertical middle cross-section of a capsule made in
accordance with a sixth embodiment of this invention; it should be noticed
that
Figure 6 also only shows the details visible in the cross-section plane and
not
those in the background; and
- Figure 7 is
a schematic vertical middle cross-section of a detail of the
capsule of Figure 1 in an assembled configuration.
With reference to the accompanying drawings, the numeral 1 denotes in its
entirety
a capsule 1 for making beverages in accordance with this invention.
As indicated, this invention relates to a capsule 1 for making beverages
comprising at least one powdered food substance (not illustrated in the
accompanying drawings) which can be extracted by passing water through it to
make a beverage. The powdered food substance, for example powdered coffee,
can be extracted for example by infusion or is soluble to make a beverage such
as coffee or tea, infusions, soups, etc. The capsule 1 may be suitable for
allowing extraction of the powdered food substance, such as coffee, by
passing pressurised water through it, for example to make an espresso coffee.
The capsule 1 comprises a substantially cup-shaped outer body 2 which in turn
comprises a lower wall 3 and a first side wall 4. In the embodiments
illustrated the
lower wall 3 of the capsule 1 mainly extends in a disk-shaped fashion and the
first
side wall 4 extends from it with a shape that to a first approximation is
frusto-
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conical, the upper part of it ending with an upper edge 5 located on the
opposite
side to the lower wall 3. A lid 6 is fixed to the outer body 2 at the upper
edge 5 and
closes the top of the outer body 2. The outer body 2 and the lid 6 of the
capsule 1
may each be made of different materials. The outer body 2 may, for example, be
made of a plastic material whilst the lid 6 may be made of an aluminium sheet
(both may consist of a single layer or multiple layers).
Inside the outer body 2, between the lid 6 and the inner surface of the outer
body
2, there is a chamber 7 in which, during use of the capsule 1, the beverage is
formed after interaction between the powdered food substance and the water.
Between a central point of the lid 6 and a central point of the lower wall 3
there is
an axis of extension 8 of the capsule 1, visible in Figures 3, 4 and 5. In all
of the
embodiments illustrated the capsule 1 is symmetrical relative to the axis of
extension 8.
Advantageously, in the embodiments illustrated, the capsule 1 is sealed in a
watertight fashion, but in use the lid 6 can be pierced to allow water to be
injected
into the capsule 1 and the lower wall 3 can also be pierced to allow the
beverage to
come out of the capsule I. Therefore, hereinafter reference will preferably be
made
to this embodiment. However, other embodiments are possible, in which the lid
6
and/or the lower wall 3 are themselves capable of allowing the water and the
beverage to pass (for example because they are pre-pierced or permeable).
The capsule 1 is therefore suitable for use in a beverage making system
which advantageously comprises a housing in which the capsule 1 can be
inserted for use for making a beverage, for example coffee. A system
suitable for using the capsule 1 illustrated comprises, in the substantially
known way, means for injecting water into the capsule 1, which can be
associated with the lid 6, comprising an injecting element such as a needle
or a blade if necessary comprising a channel for the passage of the water,
and it also comprises means for extracting the beverage from the capsule
1, which can be associated with the lower wall 3, said means in turn
comprising a piercing element for piercing/penetrating the lower wall 3 of
the capsule 1 outer body 2. In this context, the term piercing element refers
to any element, substantially of the known type, able to pierce, cut or tear,
for example a spike or a blade, fixed or mobile (again, if necessary forming
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a channel for the passage of the water). The piercing element can also pass
through the lower wall 3 of the capsule 1 centrally or, preferably, off-
centre.
The capsule 1 also comprises a filtering body 9, positioned in the chamber 7,
substantially basket-shaped, able to allow the passage of beverage through
it and at the same time to substantially retain the powdered food substance
so that, during use of the capsule 1, the beverage can pass through the
filtering body 9 and then come out of the capsule 1 (for example through a
hole made by the piercing element in the lower wall 3 or through a channel
made in the piercing element), whilst the powdered food substance can
remain substantially trapped inside.
Said filtering body 9 comprises a basket-shaped rigid or semi-rigid skeleton
10
which contains the powdered food substance, and which in turn comprises a
second side wall 11 and a bottom portion 12. The latter may in any case also
be constituted exclusively of a lower edge of the second side wall 11. The
rigid
or semi-rigid first skeleton 10 comprises openings 13 to allow fluid
communication through it. Advantageously, the openings 13 are made at least
through the second side wall 11. Depending on the embodiments, they may or
may not also be made through the bottom portion 12 (as in the cases
illustrated
in the accompanying drawings).
According to this invention, the second side wall 11 comprises a substantially
annular upper rim 14 and the bottom of the second side wall is connected to
the
bottom portion 12.
In the assembled capsule 1, the upper rim 14 is positioned close to the lid 6
of the
capsule 1 (they may or may not be in contact) and is coupled to the outer body
2
at a coupling portion 15 of the first side wall 4, which in turn is
substantially annular
and is located close to the upper edge 5 of the first side wall 4. Therefore,
advantageously, the upper rim 14 of the filtering body 9 also has a
substantially
annular extension about the axis of extension 8. The coupling between the
filtering body 9 and the capsule 1 outer body 2 is described in more detail
below.
The bottom portion 12 is in contrast positioned close to the lower wall 3 of
the outer body 2, although it is possible that there is a certain distance
between
the two, for the reasons explained below.
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In accordance with this invention the filtering body 9 therefore substantially
separates the chamber 7 into a first compartment 16 in which the powered food
substance is contained and a second compartment 17. In the preferred
embodiment the piercing element, during use, can penetrate the lower wall 3
and
be inserted in the second compartment 17 without damaging the filtering body
9. In
contrast, a piercing injecting element may pass through the lid 6 and be
inserted
directly in the first compartment 16.
Advantageously, as shown in the accompanying drawings, the upper rim 14 of
the filtering body 9 substantially delimits an access aperture to the first
compartment 16 which in the embodiments illustrated is substantially circular.
Therefore, the filtering body 9 is advantageously open at the top, that is to
say,
on the side facing towards the lid 6. During capsule 1 production, when the
lid 6
is separate from the outer body 2, the powdered food substance can therefore
be
inserted in the first compartment 16 by simply pouring it into said
compartment
through the access aperture.
Therefore, in the first compartment 16 the powered food substance interacts
with
the water injected into the capsule 1 to make the beverage. In contrast, the
second compartment 17 is intended, during use, to receive the beverage
made in the first compartment 16 and which comes out of the latter through
the filtering body 9.
In accordance with this invention, the first compartment 16 is delimited at
least
between the filtering body 9 and the lid 6 (Figures 3 and 4). However, in many
preferred embodiments the first compartment 16 may also be delimited by a
small annular portion of the first side wall 4 located between the upper edge
5 of
the first side wall 4 itself and the coupling portion 15 (which, as indicated,
is in
any case close to the upper edge 5 - Figure 7). The first compartment 16 is
therefore at least mainly delimited by the filtering body 9, and
advantageously
extends over most of the volume of the chamber 7.
According to this invention, the second side wall 11 is at least partly
distanced
from the first side wall 4 (being side by side with and opposite to it) for
allowing the
beverage to flow between them towards the lower wall 3. Advantageously, the
openings 13 through the second side wall 11 are made at least at the part of
the
second side wall 11 which is distanced from the first side wall 4. In this
way, the
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openings 13 allow a reduction, compared with prior art capsules, in the
average
distance that the water must cover through the powdered food substance in
order
to be able to come out of the filtering body 9 in the form of the beverage,
with the
advantage that the water encounters less resistance to its passage through the
substance. Consequently, the filtering body 9 allows improved filtering of the
beverage, a reduced tendency of the powdered food substance to become
unevenly compacted and therefore more even permeation of the powdered
food substance by the water injected into the capsule 1.
The second compartment 17 is delimited between the filtering body 9, the
lower wall 3 and the portion of the first side wall 4 located between the
lower
wall 3 and the coupling portion 15, and partly extends between the first side
wall 4 and the second side wall 11. In other words, the second compartment 17
surrounds at least part of the filtering body 9. In particular, the second
compartment 17 extends along the first side wall 4 at least for most of the
distance,
measured parallel to the axis of extension 8, between the coupling portion 15
and
the lower wall 3, and therefore surrounds the filtering body 9 over most of
its
extension parallel to the axis of extension 8.
Even more advantageously, as in the embodiments illustrated in the
accompanying drawings, the second compartment 17 extends along the first
side wall 4 to the coupling portion 15. Since the filtering body 9 is coupled
to the
coupling portion 15 at the upper rim 14, the substantial totality of the
filtering body
9 is surrounded by the second compartment 17. Advantageously, the openings 13
are distributed over the entire part of the filtering body 9 surrounded by the
second compartment 17, and in particular over the entire part of the second
side
wall 11 which is opposite the second compartment 17. In the embodiments
illustrated, advantageously, the openings 13 are evenly distributed around the
filtering body 9 and are grouped together in groups which are in turn
substantially distributed in an even way along the extension of the second
side
wall 11 between the upper rim 14 and the bottom portion 12.
However, advantageously, all of the openings 13 made in the second side wall
11 are located at a height which is lower than the maximum height reached by
the
powdered substance in the first compartment 16 (where the height is measured
relative to the lower wall 3), in such a way as to prevent the water from
reaching
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the openings 13 without having to pass through the powdered substance.
As already indicated, the filtering body 9 is coupled to the first side wall 4
at the
coupling portion 15. The coupling may be made in various ways.
In the case in Figures 3 and 4 the coupling is only schematically illustrated
with
the upper rim 14 positioned substantially adjacent to the lid 6.
In contrast, a preferred embodiment is illustrated in the detail in Figure 7,
where
the rigid or semi-rigid skeleton 10 of the filtering body 9 comprises a
shoulder 18,
close to the upper rim 14, with substantially annular extension about the axis
of
extension 8 and projecting radially relative to the rest of the filtering body
9 (again
with reference to the axis of extension 8). In other words, seen in a cross-
section
plane passing through the axis of extension 8, the rigid or semi-rigid
skeleton 10
externally comprises an inverted step close to the upper rim 14. The filtering
body 9 advantageously rests on the coupling portion 15 by means of the
shoulder 18. In fact, in the preferred embodiment illustrated, the coupling
portion
15 comprises a counter-shoulder 19 which also has substantially annular
extension about the axis of extension 8 and which projects radially, with
reference
to the axis of extension 8, relative to the portion of the first side wall 4
adjacent to it
on the lower wall 3 side. Therefore, as shown in Figure 7, the shoulder 18
rests on
the counter-shoulder 19. In the preferred embodiment illustrated, the upper
rim 14
is coupled to an annular region 20 of the coupling portion 15 which is located
between the counter-shoulder 19 and the upper edge 5 of the first side wall 4
to
which the lid 6 is fixed. Therefore, advantageously, in the preferred
embodiment,
the filtering body 9 is in contact with the outer body 2 of the capsule 1, and
in
particular with the coupling portion 15, substantially at two annular portions
of the
rigid or semi-rigid skeleton 10, one corresponding to the upper rim 14 and
another
corresponding to the shoulder 18. In particular, the contact between the
shoulder
18 and the counter-shoulder 19 allows the filtering body 9, once inserted in
the
capsule 1 outer body 2, to stop at the counter-shoulder 19. In other words,
the
counter-shoulder 19 acts as a contact element which prevents the filtering
body 9 from being subject to further movements towards the lower wall 3 of the
capsule 1. That is particularly useful for keeping the filtering body 9 in a
predetermined position, as described in more detail below.
However the coupling is created between the filtering body 9 and the coupling
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portion 15, the filtering body 9 may be advantageously coupled to the coupling
portion 15 by mechanical interference, and in addition or alternatively, forms
a
sealed contact with it, where "sealed contact" in this context advantageously
refers
to a contact which is watertight. Moreover, the sealed contact may also be
useful during capsule 1 production. In fact, during insertion of the powdered
food
substance in the first compartment 16, a sealed contact (at the coupling
portion 15)
allows a guarantee that the powder cannot accidentally be poured into the
second
compartment 17 (which would compromise use of the capsule 1 for making the
beverage).
The coupling which uses mechanical interference and/or is sealed can be
made in various ways.
In the embodiment illustrated in the detail in Figure 7, the mechanical
interference
coupling is created between the upper rim 14 of the filtering body 9 and the
above-mentioned annular region 20 of the coupling portion 15. To show the
mechanical interference, in Figure 7 the upper rim 14 is drawn partly
overlapping
the annular region 20, In particular, that representation implies that the
interference
contact which occurs between the upper rim 14 and the annular region 20 in
reality, advantageously, requires at least one of these to be in a state of
deformation (advantageously elastic). Mechanical interference may, in fact,
preferably occur thanks to the elastic deformability of the upper rim 14
and/or of
the annular region 20, the elasticity advantageously being allowed by the
material
used to make them and/or by their shape. In the embodiment illustrated the
annular region 20, that is to say, the region of the coupling portion 15
located
between the counter-shoulder 19 and the upper edge 5, is advantageously able
to bend. In particular, the annular region 20 presses against the upper rim 14
of the
filtering body 9 thanks to the elastic deformation to which it is subjected.
As shown
in Figure 7, the annular region 20, seen in axial section, also extends at an
angle relative to the axis of extension 8: in particular proceeding from the
upper edge 5 towards the lower wall 3 the annular region 20 moves away
from the axis of extension 8. Moreover, the coupling portion 15 at the upper
edge 5 or at the part of the annular region 20 adjacent to the upper edge 5,
delimits a section, perpendicularly to the axis of extension 8, which is
advantageously less than the area delimited by the upper rim 14 also in the
plane
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perpendicular to the axis of extension 8. Advantageously, for that reason,
during
capsule 1 production the coupling portion 15, and in particular in the
preferred
embodiment its annular region 20, resists the passage of the upper rim 14
during
the end step of filtering body 9 insertion in the chamber 7. Filtering body 9
insertion in the chamber 7 therefore requires pressure to be applied on the
filtering body 9, directed towards the lower wall 3, at least as the upper rim
14
passes at the annular region 20. In the preferred embodiment illustrated,
advantageously, the pressure on the filtering body 9 is maintained until the
shoulder 18 is resting against the counter-shoulder 19, thus creating a snap-
on type insertion. That particular shape of the coupling portion 15 and its
interaction with the filtering body 9, and in particular with the upper rim
14,
advantageously prevents removal of the filtering body 9 from inside the
capsule 1
outer body 2, for example after a thrust applied on the bottom portion 12 of
the
filtering body 9 and directed towards the lid 6.
Moreover, advantageously, the sealed contact is also created between the
upper rim 14 of the filtering body 9 and the annular region 20 of the coupling
portion 15. In particular, in the embodiments illustrated, the upper rim 14
and the
annular region 20 are made in such a way that between them there is continuous
contact, and the seal is guaranteed by mechanical interference.
As already indicated, to avoid contact with the piercing element as it
penetrates
the second compartment 17 (if the lower wall 3 can be pierced), the filtering
body 9
will advantageously have a shape that allows the piercing element to enter but
at
the same time avoids contact with it, considering its dimensions, the related
stroke
and its positioning.
Advantageously, in some preferred embodiments (Figure 1 to 4), that is
achieved thanks to the fact that the bottom portion 12 of the filtering body 9
is
spaced from the lower wall 3 to allow, during capsule 1 use in a system
suitable
for using it, insertion of the piercing element in the capsule 1, through the
lower
wall 3, without the bottom portion 12 of the filtering body 9 being damaged.
Moreover, the bottom portion 12 of the filtering body 9 is preferably mainly
constituted of a substantially flat disk.
In the embodiment illustrated in Figures 1 and 7, the position of the counter-
shoulder 19 on the coupling portion 15 and the position of the shoulder 18 on
the
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filtering body 9, are established to determine a distance between the lower
wall 3
of the outer body 2 and the bottom portion 12 of the filtering body 9 which is
greater than the distance between the tip of the piercing element and the
lower
wall 3 when the piercing element is inserted in the capsule 1.
Alternatively, the bottom portion 12 may comprise a recess 21 towards the lid
6 in
which the piercing element can be inserted. The dimensions of the recess 21
will
be proportionate to those of the piercing element and to the related stroke
that it
must cover inside the capsule 1 (the distance between the lower wall 3 and the
tip
of the piercing element, when the latter is inserted in the capsule 1).
Depending if
the piercing element passes through the lower wall 3 centrally or off-centre,
the recess 21 will be located respectively at the centre of the bottom portion
12 or off-centre relative to the axis of extension 8, in the latter case
having
an extension that is advantageously annular about it. This configuration is
illustrated in Figure 5 where the bottom portion 12 comprises an outer annular
zone 22 and an inner zone 23; the outer annular zone 22 being spaced or away
from the lower wall 3, whilst the inner zone 23 is close to the lower wall 3.
Alternatively to the presence of an annular recess 21 (therefore when the
piercing element is off-centre relative to the axis of extension 8), the
filtering
body 9 may have a substantially conical shape, the taper being such that it
prevents contact with the piercing element even when it is completely
inserted (considering its maximum stroke) in the second compartment 17.
Again with reference to the shape of the filtering body 9, as already
indicated, the
top of it is in contact with the first side wall 4 at the coupling portion 15.
In
contrast, the bottom of the filtering body 9 is spaced from the first side
wall 4, that
is to say, between the first side wall 4 of the outer body 2 and the second
side
wall 11 of the filtering body 9 there is an empty space which corresponds to
the
part of the second compartment 17 positioned between the first side wall 4 and
the filtering body 9. Advantageously, the distance between the filtering body
9 and
the first side wall 4 at the second compartment 17 increases proceeding
towards
the bottom portion 12. For example, if the first side wall 4 extends in a
substantially
conical fashion with reference to the axis of extension 8, proceeding from the
lid 6
towards the lower wall 3, the second side wall 11 of the filtering body 9 may
have a
similar extension but with a more pronounced taper (Figures 1 and 2).
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Moreover, in the embodiments illustrated, the second side wall 11 of the
filtering
body 9 has the structure of superposed rings 24, which are concentric about
the
axis of extension 8 and connected to each other. Each ring 24, proceeding from
the upper rim 14 towards the bottom portion 12 of the filtering body 9,
delimits a
respective section of the first compartment 16, in a plane substantially
perpendicular to the axis of extension 8, having an area greater than that
delimited by the next ring 24. Advantageously, in the embodiments illustrated
in
Figures 1 and 2, the same ring 24 delimits various sections of the first
compartment 16 (which are perpendicular to the axis of extension 8) which have
decreasing areas proceeding in the direction from the upper rim 14 towards the
bottom portion 12. In other words, each ring 24, proceeding from the upper rim
14
towards the bottom portion 12, moves closer to the axis of extension 8. In the
e preferred embodiment illustrated, each section delimited by a ring 24 is
substantially circular and its centre is identified by the intersection with
the axis
of extension 8.
Said structure of the second side wall 11 of the rigid or semi-rigid skeleton
10
gives it rigidity and makes its production easier, which advantageously can be
carried out using injection moulding.
The second side wall 11, seen in radial section relative to the axis of
extension 8,
therefore comprises, on the side facing towards the first compartment 16, a
substantially stepped profile, each step corresponding to one of the rings 24.
Advantageously, even on the side facing towards the first side wall 4 the
second
side wall 11 of the filtering body 9 comprises a stepped profile, each step
radially
recessed, with reference to the axis of extension 8, relative to the adjacent
step
positioned between it and the upper rim 14. In other words, the second side
wall
11 of the filtering body 9 comprises inner steps, formed by the rings 24, and
outer steps, facing towards the first side wall 4. As shown in Figures 1 and
2, the
inner steps and the outer steps may not be aligned with each other. In
particular, in
the first and second embodiments each outer step extends substantially from
approximately half the height, measured parallel to the axis of extension 8,
of each
ring 24. However, in other embodiments, other second side wall 11
configurations
and structures are possible, such as those schematically illustrated in
Figures 3, 4
and 5.
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In the first and second embodiments the filtering body 9 also comprises ribs
25 for
stiffening it which, advantageously, are located at least on the second side
wall 11
of the rigid or semi-rigid skeleton 10. As shown in Figures 1 and 2,
advantageously, the ribs 25 of the second side wall 11 extend
longitudinally from the upper rim 14 at least to the bottom portion 12 and
lie substantially in planes passing through the axis of extension 8.
Preferably, the ribs 25 also extend on the bottom portion 12. In the preferred
embodiments illustrated, more precisely, some ribs 25 extend over radial
stretches
(with reference to the axis of extension 8) on the bottom portion 12 whilst
other ribs
25 extend over annular stretches about the axis of extension 8. The ribs 25
with
annular extension and radial extension may meet one another, as shown in
Figures 1 and 2. Some ribs 25 of the bottom portion 12 which extend radially
may
also extend from the ribs 25 of the second side wall 11.
In the embodiments illustrated, the ribs 25 of the second side wall 11 extend
on
the rings 24 and on the outer steps in which the second side wall 11 is
structured
and they project radially relative to the latter, creating an overall frusto-
conical
shape: in other words, each rib 25 is angled in such a way that, proceeding
from
the upper rim 14 towards the bottom portion 12 of the filtering body 9, the
distance
between its outer surface and the capsule 1 axis of extension 8 is reduced.
In the preferred embodiment the ribs 25 do not make contact with the capsule 1
outer body 2, except at the coupling portion 15. However, in general the
filtering
body 9 may be in contact with the capsule 1 outer body 2 even at points other
than
the coupling portion 15, such as the outer surface of the ribs 25, provided
that
there is no interruption in the fluid communication both through the filtering
body 9
and with the beverage outfeed zone through the lower wall 3. Therefore, in
some
embodiments, one or more of the ribs 25 present on the second side wall 11
and/or
on the bottom portion 12 may be in contact with the capsule 1 outer body 2:
for
example the longitudinal ribs 25 present on the second side wall 11 could be
in
contact at one or more points with the first side wall, whilst between one rib
25 and
another the filtering body 9 is distanced from the first side wall 4.
As already indicated, the rigid or semi-rigid skeleton 10 comprises openings
13
which allow fluid communication, that is to say which allow the passage of the
beverage from the first compartment 16 towards the second compartment 17.
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As already indicated, the openings 13 are located at least on the second side
wall
11. In the preferred embodiments illustrated, there are several openings 13 on
each of the rings 24 of the rigid or semi-rigid skeleton 10. In the
embodiments
illustrated, in particular, the openings 13 made in the second side wall 11
are
formed by slits extending mainly parallel to the axis of extension 8, being
arranged side by side. As shown in the accompanying drawings, Figures 3 to 5,
the
slits extend substantially over the entire height of each ring 24 (and
therefore of
each inner step). In contrast, in the first and second embodiments, each
through
slit only extends over a portion of each ring 24.
As already indicated, the openings 13 are advantageously also made in the
bottom
portion 12 (which mainly has the shape of a flat disk). In the embodiments
illustrated, said openings 13 are elongate slots extending on the bottom
portion 12
in directions which are radial relative to the axis of extension 8.
However, more generally, whatever the shape of the filtering body 9 and
wherever
the openings 13 are positioned, they may have a different shape, orientation,
arrangement and dimensions, for example, they may be circular holes, or cross-
shaped, elongate slits, curves, etc. Moreover, the rigid or semi-rigid
skeleton 10
may comprise different types of openings 13.
Finally, according to this invention, the filtering body 9 also comprises at
least one
layer 26 of flexible filtering material applied to the rigid or semi-rigid
skeleton 10 for
in use intercepting the beverage which comes out of at least several openings
13 of
the filtering body 9 and flows towards the lower wall 3 and for filtering said
beverage.
In particular, depending on the embodiments, the layer 26 may be applied
directly
at least at several openings 13 of the rigid skeleton 10, or it may be
operatively
associated with them in a different way, as described in more detail below
with
reference to the embodiment in Figure 6. Said flexible filtering material may,
for
example, be non-woven fabric, fabric, paper, etc.
Depending on the embodiments, the openings 13 to which the layer 26 of
flexible filtering material is applied or with which it is operatively
associated may
have a shape and/or size allowing the passage of the powdered food substance
through them. In contrast, in the preferred embodiments that is not the case
and all of the openings 13 are of a size such that they act as a filter for
the
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16
powdered food substance, to retain it at least when it is larger than a
predetermined particle size (the size of the openings usually being less than
the nominal size of the powdered substance).
In contrast, the openings 13 to which the layer 26 of flexible filtering
material is
not applied or with which it is not operatively associated will always be of a
size such that they act as a filter for the powdered food substance, to retain
it
at least when it is larger than a predetermined particle size.
In the case in which the layer 26 is applied at the openings 13, and the rigid
or
semi-rigid skeleton 10 also comprises openings 13 through the bottom portion
12, depending on requirements, either the layer 26 of flexible filtering
material is
applied exclusively at all of the openings 13 made through the bottom portion
12 and in contrast the openings 13 made in the second side wall 11 are of a
size such that they act as a filter for the powdered food substance (Figures
1, 3
and 5), or the layer 26 of flexible filtering material is applied exclusively
at all of
the openings 13 made through the second side wall 11 of the rigid or semi-
rigid
skeleton 10 and the openings 13 made in the bottom portion 12 in contrast are
of a size such that they act as a filter for the powdered food substance.
Although the choice amongst the two solutions depends on the production
requirements dictated on each occasion by the features of the powdered food
substance used, in general the former is preferable.
In contrast, according to a further embodiment illustrated in Figures 2 and 4,
the
layer 26 of flexible filtering material is applied at all of the openings 13
made
through the rigid or semi-rigid skeleton 10. In particular, in the embodiments
illustrated that is achieved by also shaping the flexible filtering material
in a
basket-shaped single piece.
In the case in which the bottom portion 12 comprises a recess 21 (as in the
case
in Figure 5), the layer 26 of flexible filtering material may be shaped to
follow
the shape of the bottom portion 12.
In other embodiments not illustrated, the flexible material may instead be
used
in a plurality of smaller pieces, each fixed to the rigid or semi-rigid
skeleton 10 at
one or more openings 13.
In contrast, in the embodiment in Figure 6, the layer 26 is not applied
directly at
the openings 13, instead it is distanced from them for intercepting the
beverage
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only after it has passed into the second compartment 17. In particular, in
this
embodiment the bottom of the rigid or semi-rigid skeleton 10 comprises a
projection 27 coupled in a sealed fashion to the first side wall 4. In turn,
the
projection 27 defines one or more passages 28 in fluid communication with said
at
least several openings 13, and the layer 26 of flexible filtering material is
coupled
to the one or more passages 28 for intercepting all of the beverage which
comes
out of said at least several openings 13 and which flows towards the lower
wall 3.
In particular, in the embodiment in Figure 6, the projection 27 and the layer
26
together form a filtering septum which is interposed between the bottom
portion 12
and the lower wall 3 for intercepting the beverage coming out of all of the
openings
13, and which comprises a perimetric edge 29 which in turn is coupled in a
sealed
fashion to the first side wall 4 and forms a single passage 28 closed by the
layer
26.
However, advantageously, in the preferred embodiments of this invention, on
one
hand all of the openings 13 are of a size such that they act as a filter for
the
powdered food substance, for retaining it at least when it is above a
predetermined
particle size, and on the other hand, the layer 26 of flexible filtering
material is
applied either only at openings 13 made in the bottom portion 12 or at all of
the
openings 13.
Fixing of the flexible filtering material to the rigid or semi-rigid skeleton
10 can
advantageously be achieved in any way suitable for the purpose, for example by
sealing, gluing, or moulding the rigid or semi-rigid skeleton 10 directly on
the
layer 26 of material.
However, in general, advantageously fixing of the flexible filtering material
to the
rigid or semi-rigid skeleton 10 occurs for each piece along a continuous line
which completely surrounds the openings 13 or the passages 28 involved, in
such
a way as to prevent the formation of passages 28 which may allow the beverage
to pass from the openings 13 to the lower wall 3 without going through the at
least one layer 26 of flexible filtering material.
As indicated, the capsule 1 is suitable for use in a capsule-based beverage
making system which comprises water injecting means that can be associated
with the lid 6 of the capsule 1 and beverage extracting means which can be
associated with the lower wall 3 of the capsule 1. In particular, in the
preferred
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embodiment, an injecting element which pierces the lid 6 is used to inject the
water into the first compartment 16 which contains the powdered food
substance. The water interacts with the powdered food substance, making the
beverage which, driven by the water flow (which may be pressurised), passes
through the powder, covering stretches of it until it reaches the openings 13
present
in the filtering body 9, and if necessary the subsequent layer 26 of flexible
filtering
material. While the powdered food substance at least mainly remains confined
in the first compartment 16, the beverage passes through the openings 13 from
the first compartment 16 to the second compartment 17, where it can come out
of the capsule 1 after the action of the piercing element which penetrates the
lower wall 3. Depending on the type of beverage making system, the beverage
may come out through the hole left by the piercing element or through a
channel present in said element.
Any granules of powder which manage to pass beyond the openings 13 with
which the layer 26 of flexible filtering material is associated, are then
retained by
the latter. Unlike what happens in prior art capsules equipped with filters
made
of flexible filtering material, in the preferred embodiment in which said
openings
13 are of a size such that they act as a filter for the powdered food
substance,
to retain it at least when it is larger than a predetermined particle size, it
is
possible to avoid any clogging of the layer 26 since most of the powdered
substance is retained directly by the rigid or semi-rigid skeleton 10.
This invention brings important advantages.
The basket shape of the filtering element and the presence of the openings in
the
second side wall allow a reduction in the average distance that the water must
cover through the powdered food substance in order to be able to come out of
the
filtering body. For example, the beverage made close to the lid is not forced
to
pass through substantially all of the powdered food substance in order to be
able to come out through the bottom portion of the filtering body, but can
come
out through the above-mentioned openings closest to it. In that way, the
beverage encounters less resistance during its movement. Moreover, in that
way,
the risk of the formation of highly compacted areas linked to the
substantially
unidirectional flow of water and beverage is reduced. In this way, while the
beverage is being made the powdered food substance maintains substantially
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even compactness, consequently reducing the risk of the formation of
preferential
water flow channels, and the water can therefore permeate the food substance
more evenly and homogeneously, leading to an increase in the quality of the
beverage made.
The combination of the flexible filtering material with at least several of
the
openings allows a reduction, or even elimination, of micro-granules of powder
coming out with the beverage.
Added to that is the fact that the filtering body of the capsule according to
this
invention, thanks to its shape and the presence of the above-mentioned
openings,
comprises a filtering surface greater than that of a common flat filtering
body (the
dimensions of the capsule being the same), while keeping the quantity of
powdered food substance contained in it substantially unchanged. That allows
improved filtering of the beverage.
Finally, it should be noticed that this invention is relatively easy to
produce and
that even the cost linked to implementing the invention is not very high.
The invention described above may be modified and adapted in several ways
without thereby departing from the scope of the inventive concept.
Moreover, all details of the invention may be substituted with other
technically equivalent elements and the materials used, as well as the
shapes and dimensions of the various components, may vary according to
requirements.
