GB2569618A

GB2569618A - Beverage or food product cartridge

Info

Publication number: GB2569618A
Application number: GB1721619.3A
Authority: GB
Inventors: Norton Mark; York Geoffrey
Original assignee: Koninklijke Douwe Egberts BV
Current assignee: Koninklijke Douwe Egberts BV
Priority date: 2017-12-21
Filing date: 2017-12-21
Publication date: 2019-06-26
Also published as: GB201721619D0

Abstract

A kit for the self-assembly of a beverage machine cartridge. The kit comprises a reusable cap 12, configured to locate the cartridge in the machine, and a disposable capsule 11, configured to hold beverage ingredients. The cap 12 and capsule 11 can releasably engage to form the cartridge, and there may be sealing means 48 on the cap. The shape of the outer periphery of the cap 12 or recesses 29, 30 on its base 20 may be used to locate the cartridge in the machine. The cap 12 may have a fluid inlet arrangement 26 and a fluid outlet 27 and the capsule may have a filter 87. The cap 12 may comprise an interlocking base and retaining element (320 and 352, figure 16). The cartridge may entrain air into the beverage, using a slot (496, figure 18) in the cap 12 that co-operates with a corresponding part in the capsule 11 to form in an eductor. A lid may need to be removed from the disposable capsule 11 before engaging the cap 12. A method of dispensing a beverage is claimed.

Description

BEVERAGE OR FOOD PRODUCT CARTRIDGE

Technical Field

This disclosure is directed towards a beverage or food product cartridge, in particular a cartridge formed from two or more parts and for use in a machine for preparing a beverage or food product.

Background

Coffee houses have been a part of the coffee culture since the 17th century. Throughout the years methods of making coffee have been refined and skilled people trained to produce the best coffee beverages. The first coffee machines were developed in the early 1800s and an automatic espresso machine was invented in the 1930s. The automation of the coffee making process has, in turn, lead to a rapid growth, particularly in the last ten years, in the number of coffee houses/shops with more specialist drinks, such as espresso and cappuccino, being in high demand. These types of beverages have historically been regarded as luxury items because of the need for expensive, complex machines capable of producing the high pressures necessary for making them, which had to be properly operated and maintained by a trained barista to produce good quality. Coffee aficionados agree that an espresso can be spoiled by a badly trained operator despite the use of a good quality machine and good quality coffee. This trend, however, has not only lead to an increased demand from consumers for luxury top quality beverages, but also a desire for a greater variety of speciality beverages, and the ability to make such beverages in the comfort of one's own home.

As a result, beverage preparation systems, such as coffee, tea or hot chocolate brewing machines, are now well known. Typically a beverage preparation system provides a serving of a particular beverage into a receptacle, such as a cup. The beverage ingredients are placed in a brewing chamber and a fluid medium, such as water or steam, is transferred into the brewing chamber. The fluid medium may be injected into the brewing chamber under relatively high pressure or temperature in order to extract the constituents from the beverage ingredients. The beverage then flows from the brewing chamber and into the receptacle. Such systems can be used in the commercial or domestic markets and can also be used in the preparation of certain types of food products, such as milk based desserts and the like.

The beverage ingredients are typically provided either from a bulk supply of beverage ingredients or from individual packages of beverage ingredients such as pods, capsules or cartridges. A common beverage preparation system comprises a beverage preparation machine and rigid or semi-rigid capsules wherein a brewing chamber is located inside each of the capsules. The beverage ingredients are packed and sealed inside the brewing chamber prior to use. The seal maintains the quality of the beverage by preventing the exposure of the ingredients to air and moisture. A capsule is placed in the beverage preparation machine and the seal is pierced to form an inlet and an outlet. The beverage machine transfers a fluid via the inlet into the brewing chamber inside the capsule. The fluid contacts the beverage ingredients and, by brewing, mixing, dissolving or suspending of the ingredients in the fluid, forms a prepared beverage. The prepared beverage is then transferred out of the brewing chamber from the capsule outlet and into a receptacle. Many of such beverage preparation systems dispense a single serving per capsule.

One such beverage preparation system is disclosed in EP-B-1715779. The document discloses a beverage preparation machine comprising a brew head and cartridges comprising a laminate, an outer member and an inner member. The brew head comprises a holder for holding a cartridge and inlet and outlet piercers for piercing the laminate of the cartridge. The operation of the system starts with the insertion of a cartridge into the holder. When the holder is closed, the piercers pierce the laminate of the cartridge to connect an inlet and outlet of the cartridge with the brew head. A dispense cycle is then performed, which typically involves four main stages. In a pre-wet stage the cartridge is charged with water from a water tank by a water pump to wet the beverage ingredients. During a pause stage the water is allowed to soak into the ingredients to increase the yield of extractables from the ingredients. In a brew/mixing stage water heated by a water heater is passed through the cartridge, the beverage is formed inside the cartridge and then the beverage is dispensed from the cartridge. In a purge stage pressurised air is blown through the machine to ensure that all of the beverage is dispensed from the cartridge and that the flow path is clear for dispensing another beverage. Finally, the cartridge is removed from the machine.

The cartridge disclosed in EP-B-1715779 contains ingredients for the preparation of a single beverage and therefore can only be used in the beverage preparation machine for a single dispense cycle. By using a single cartridge for the preparation of a single beverage, the seal is only broken just prior to preparing each beverage and thereby the ingredients are kept as fresh as possible. This improves the quality of the prepared beverage. The use of this type of cartridge has more recently also been extended to preparing food products, such as custards or other milk based products. However, the preparation of different products requires a number of different cartridges, which means that a relatively large amount of the material forming the cartridges may be used. It is highly desirable to reduce the amount of packaging material used, both in terms of reduction of waste products which need to be disposed of and to reduce packaging costs.

It is, therefore, an object of the present disclosure to reduce the amount of packaging material used in a cartridge used for the preparation of a beverage or food product whilst maintaining the product quality.

Summary

In a first aspect the present disclosure provides a kit for the self-assembly of a cartridge for use in a machine for preparing food or beverage products, the kit comprising a reusable cap and a disposable capsule. The reusable cap is configured to locate the cartridge in the machine. The disposable capsule is configured to hold beverage ingredients. The reusable cap and disposable capsule are releasably engagable to form the cartridge.

Preferably, the reusable cap and the disposable capsule are configured such that a means for entraining air into the beverage is formed between the reusable cap and the disposable capsule when the reusable cap and disposable capsule are engaged.

Preferably, the means for entraining air into the beverage comprises a slot formed in the reusable cap for co-operation with a corresponding part of the disposable capsule to form an eductor.

Preferably, the reusable cap comprises a base and a retaining element, wherein the base is configured to releasably interlock with the retaining element to retain at least a portion of the disposable capsule between the base and the retaining element in use. The base and the retaining element may be provided with complementary interlocking means. The disposable capsule and reusable cap may be provided with complementary interlocking means. The complementary interlocking means comprise a screw thread or a bayonet element or a twist-to-lock element. The complementary interlocking means comprise a releasable push-fit element or releasable latch element. The reusable cap and disposable capsule may be configured to be slidably engagable by lateral movement of one or both of the disposable capsule and the reusable cap relative to the other of the disposable capsule and the reusable cap.

In a second aspect the present disclosure provides reusable cap for use in the kit. Preferably, the reusable cap comprises a slot for co-operation with a corresponding part of a disposable capsule to form an eductor.

Preferably, the reusable cap comprises interlocking means for interlocking with a disposable capsule. The reusable cap may comprise a base and a retaining element, wherein the base is configured to releasably interlock with the retaining element for retaining a disposable capsule between the base and the retaining element in use.

Preferably, the base and the retaining element are provided with complementary interlocking means. The complementary interlocking means may comprise a screw thread or a bayonet element or a twist-to-lock element. The complementary interlocking means may comprise a releasable push-fit element or releasable latch element.

Preferably, the reusable cap has an outer periphery the shape of which is configured to assist in the location of the cartridge in a machine. The reusable cap may have a base which is provided with recesses which are configured to assist in the location of the cartridge in a machine.

Preferably, the reusable cap comprises a fluid inlet configured for communication with fluid injection means of a machine in which it is located. Preferably, the reusable cap comprises an outlet for the delivery of a prepared food or beverage product. Preferably, the reusable cap comprises a cavity which is open when the disposable capsule is not engaged with the reusable cap. The reusable cap may comprise means defining a fluid flow path from the fluid inlet to the cavity.

Preferably, the reusable cap comprises sealing means against which members of the disposable capsule abut when the reusable cap and disposable capsule are engaged.

In a third aspect the present disclosure provides a disposable capsule for use in the kit comprising a chamber containing at least one beverage or food ingredient. Preferably, the chamber is sealed with a removable lid which must be removed before engagement of the disposable capsule and the reusable cap. Preferably, a cap inlet cavity communicates with the chamber when the disposable capsule and reusable cap are engaged. Preferably, the disposable capsule comprises further comprising means defining a fluid flow path from the chamber to an outlet which, when the disposable capsule and reusable cap are engaged, communicates with a cap outlet aperture.

In a fourth aspect the present disclosure provides a cartridge for use in a machine for preparing food or beverage products comprising the reusable cap engaged with the disposable capsule.

In a fifth aspect the present disclosure provides a method of dispensing a beverage or food product during an operating cycle from a cartridge assembled from a kit according to the present disclosure, the method comprising the steps of engaging the reusable cap and the disposable capsule, injecting a liquid through a fluid inlet in the reusable cap, passing the liquid through the disposable capsule and dispensing the beverage or food product out of an outlet in the reusable cap and into a receptacle.

In a sixth aspect the present disclosure provides a beverage or food dispensing system comprising a cartridge assembled from a kit according to the present disclosure and a beverage or food dispensing machine adapted to receive the cartridge and to dispense a beverage or food product therefrom by the addition of a liquid.

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.

Brief Description of the Drawings

Figure 1 is a perspective view of a first embodiment of a cartridge of the present disclosure;

Figure 2 is a perspective view of a cap of the cartridge of Figure 1;

Figure 3 is a cross-sectional perspective view of the cap;

Figure 4 is a cross-sectional front view of the cap;

Figure 5 is a perspective view of the underside of the cap;

Figure 6 is a perspective view of a capsule of the cartridge of Figure 1;

Figure 7 is a top view of the capsule;

Figure 8 is a bottom view of the capsule;

Figure 9 is a cross-sectional front view of a capsule of the cartridge ;

Figure 10 is a cross-sectional perspective view of the underside of the capsule with a removable lid omitted;

Figure 11 is a perspective view of the underside of an outer member of the capsule of Figures 6 to 10;

Figure 12 is a perspective view of an inner member of the capsule of Figures 6 to 10;

Figure 13 is a cross-sectional front view of the cartridge of the present disclosure;

Figure 14a is a perspective view of a cartridge of Figure 1, illustrating the cartridge assembly method.

Figure 14b is a partial sectional view of the cartridge of Figure 14a;

Figure 14c is a further view of the cartridge of Figure 14a illustrating the cartridge disassembly method;

Figure 14d is a partial sectional view of a cartridge of the present disclosure;

Figure 15a is a schematic representation of a cap and capsule of a third embodiment of the present disclosure;

Figure 15b is a further schematic representation of the cap and capsule of Figure 15a;

Figure 16 is a section view of a further embodiment of the cartridge of the present disclosure;

Figure 17s and 18 are section views showing an eductor means for the cartridge of the present disclosure;

Figures 19a and 19b are section views of a cartridge interlocking means of the present disclosure;

Figures 20a and 20b illustrate interlocking of the cartridge interlocking means of Figures 19a and 19b.

Detailed Description

The present disclose is generally directed towards a two- or three-part cartridge for the preparation of beverage or food products for use in a machine, the cartridge comprising a disposable capsule and a reusable cap. Generally the reusable cap may comprise one or two parts. Each part of the cartridge may itself be formed from one or more components assembled to form the part.

The disposable capsule contains the beverage or food ingredients and, during use, is sealably interlocked with the cap. To prepare the product the cartridge is placed in a holder of the machine. The holder is closed and a brewing liquid is introduced into the cartridge for the preparation of the product. A discharge cycle is then carried out and the prepared beverage or food product flows out of the cartridge and into a receptacle. Finally, the holder is opened and the cartridge is taken out. The disposable capsule is unlocked from the cap and disposed of. The disposable capsule is generally for single use, whereas the reusable cap is designed to be used a plurality of times.

The two- or three- part cartridge disclosed herein is particularly suitable for use in the beverage preparation machine disclosed in EP-B-1715779, the contents of which are incorporated herein by reference. However, it is envisaged that the cartridge may be used in other machines. It is further envisaged that the features of the cartridge disclosed herein may be arranged in a different manner in order to render the cartridge suitable for use in other machines. In particular, the shape and location of the features may be different.

A cartridge according to a first embodiment of the disclosure is illustrated in Figure 1. The cartridge 10 comprises a disposable capsule 11 and a reusable cap 12, the disposable capsule 11 having means for engaging the reusable cap 12.

The reusable cap 12 is illustrated in greater detail in Figures 2 to 5 and comprises a base 20 and an annular wall 21. The base 20 comprises a flange 22, which is a substantially annular plate around the periphery of the base 20 and is shaped to fit inside a recess in the cartridge mount of the beverage preparation machine. The flange 22

- 8 preferably comprises a horizontally protruding handle 23, which is for locating in a complementary shaped recess in the cartridge mount. This prevents the reusable cap 12 from rotating about the vertical axis and thereby ensures that the reusable cap 12 is oriented correctly on the cartridge mount.

The base 20 further comprises an annular ring portion 24 which is located within the flange 22 and the annular wall 21 is located on the annular ring portion 24. The annular ring portion 24 comprises an annular shoulder 25 and a fluid inlet arrangement 26 which provides a flow path for a liquid into the cartridge 10. The annular ring portion 24 has an external wall 34 and an inner wall 36 which is substantially parallel to the external wall 34, defining a recess 29 therebetween. An annular member 35 joins the two walls 34, 36 at one edge.

The base 20 further comprises an outlet aperture 27 located substantially in the middle thereof, which provides a flow path for the prepared food or beverage product out of the cartridge 10. An outlet aperture wall 28 surrounds the outlet aperture 27 and an inlet cavity 31 is defined between the outer face of outlet aperture wall 28 and an inner wall 36 of the annular ring portion 24 and the annular wall 21. The top of the inlet cavity 31 is open when the capsule 11 is not interlocked with the cap 12. A further recess 30 is defined in an underside of the base 20.

The recesses 29, 30 are used to locate the reusable cap 12 accurately on the cartridge mount in the machine which is provided with complimentary protrusions. In the embodiment shown, the relatively deep annular recess 29 is generally located under the annular shoulder 25. The relatively shallow annular recess 30 is generally located under the inlet cavity 31. The recesses 29, 30 project upwardly into the underside of the annular ring portion 24, thereby reducing the amount of material required to form the reusable cap 12.

The reusable cap 12 may further comprise mounts 32 on the underside of the base 20 for recognition means 33. The mounts 32 provide a flat surface on which recognition means 33 may be at least partially located over the recesses 29, 30. In the embodiment shown, there are two mounts 32 shaped as rectangular cuboids and the lower surface of the mounts 32 are flush with the lower surface of the flange 22. The recognition means 33 may be similar to those described in EP-B-1715779. In one embodiment recognition means 33 comprise a barcode and an optical barcode reader is employed on the machine to identify the ingredients contained in a cartridge 10 inserted into the machine. In an alternative embodiment, an RFID code is located on the underside of the reusable cap 12 and an RFID reader is employed by the machine.

The inner diameter of the annular wall 21 is slightly larger than the diameter of the inner wall 36, such that a step 40 is formed on the annular ring portion 24 projecting inwardly relative to the annular wall 21. Cap interlocking means 41 are provided on the inner side of the annular wall 21. The cap interlocking means 41 comprise at least one inwardly directed protrusion located on inner side of the annular wall 21. Each protrusion may be in the form of a curved bar extending longitudinally around the inner side of the annular wall 21.

The cap interlocking means 41 may comprise a plurality of protrusions located at regular intervals around the inner side of the annular wall 21, the protrusions being separated by spaces sized to allow capsule interlocking means 75 of the disposable capsule 11 to pass between the protrusions. The cap interlocking means 41 further comprise stops 42, preferably comprised of a relatively small downward lip on the underside, and at the end, of each protrusion.

The fluid inlet arrangement 26 comprises a primary inlet aperture 43 (see Figure

3), a primary inlet duct 44, a plurality of cavity inlet apertures 45 and a plurality of cavity inlet ducts 46. The primary inlet aperture 43 is located in the underside of the base 20 and at least partially underlies the flange 22 and the annular ring portion 24. In one embodiment, the primary inlet duct 44 extends through the entire height of the base 20 and the top of the primary inlet duct 44 is covered by a lid 47, which extends outwardly from the annular wall 21. The plurality of cavity inlet apertures 45 are located on an inside face of the inner wall 36 of annular ring portion 24 and the cavity inlet ducts 46 extend from the cavity inlet apertures 45 through the inner wall 36 of the annular ring portion 24 to the top of the primary inlet duct 44.

The fluid inlet arrangement 26 is arranged to provide a fluid flow path from the primary inlet aperture 43, through the primary inlet duct 44, through the plurality of cavity inlet ducts 46, through the plurality of cavity inlet apertures 45 and into the inlet cavity 31. There can be any number of cavity inlet apertures 45 and cavity inlet ducts 46, provided that fluid can exit through the cavity inlet apertures 45 to steadily flood the inlet cavity 31. In the embodiment shown in the Figures there are three cavity inlet apertures 45 and three cavity inlet ducts 46. A single, large, cavity inlet aperture 45 and cavity inlet duct 46 could be used, although a plurality of each provides additional structural support to the base 20.

Minor and major ring seals 48, 49 are provided on the top of the outlet aperture wall 28 and on the step 40 respectively. The ring seals 48, 49 are preferably formed from a rubber and form a compression seal when the disposable capsule 11 is interlocked with the reusable cap 12. Preferably, the rubber should be food safe and suitable for beverage machine brewing conditions.

The features of reusable cap 12 are preferably formed unitary as one single part or alternatively as separate parts. In the embodiment shown, for example, the base 20 may form a first part and the annular wall 21 may form a second part, and the first and second parts are joined to one another by heat welding or an adhesive. In other embodiments the parts may be joined to one another by a mechanical fixing means, such as a screw, nut and bolt or rivet.

The disposable capsule 11 is illustrated in greater detail in Figures 6 to 12. The disposable capsule 11 comprises an inner member 60 (see Figure 9), an outer member 61, a removable lid 62 and a membrane 63. The outer member 61 is generally bowlshaped having a top wall 65, an annular side wall 66 and an open bottom 67. The diameter of the open bottom 67 is greater than the diameter of the top wall 65, such that the diameter of the annular side wall 66 decreases as one traverses from the bottom 67 to the top wall 65. The annular side wall 66 and top wall 65 define an interior 68 of the outer member 61.

A recessed section 69 is formed in the centre of the top wall 65, thereby defining an aperture 70 in the top wall 65. The recessed section 69 is preferably frusto-conical in shape and tapers inwardly. The end of the recessed section 69 is closed off by a wall having a first portion 71, a second portion 72 and a third portion 73. The first portion 71 is an annular disc; the second portion 72 is a short tubular section projecting from the inside edge of the first portion 71; and the third portion 73 is a disc covering the end of the second portion 72. In a preferred embodiment the edges defined between the top wall 65, the recessed section 69 and the first, second and third portions 71,72, 73 are chamfers or fillets.

An outwardly directed flange 74 is located around the periphery of the annular side wall 66 and one or more capsule interlocking means 75 are provided around its outer circumference.

In a preferred embodiment, the capsule interlocking means 75 comprises one or more outwardly directed protrusions extending longitudinally around the outer edge of the flange 74. The shape and position of the capsule interlocking means 75 is adapted such that they can interlock with the cap interlocking means 41 on the reusable cap 12. The protrusions are separated by spaces sized to allow cap interlocking means 41 of the reusable capsule 12 to pass between the protrusions.

The inner member 60 is located inside the outer member 61 and comprises an annular support member 80, a funnel 81 and a filter 87. As shown in Figures 12 and 13, the annular support member 80 comprises an inner annular hub 82, from which project a plurality of radial spokes 83 which are attached at their other ends to an annular outer rim 80. This arrangement defines a plurality of filtration apertures 85 and an outer rim 86. A support rib 84 extends along the underside of each radial spoke 83 to provide additional strength. In one embodiment there are ten radial spokes 83 and therefore ten filtration apertures 85.

The filter 87 is disposed on the underside of the annular support member 80 and covers the filtration apertures 85. Figure 10 shows the filter 87 partially removed from the annular support member 80. In one embodiment the filter 87 is formed of a single annulus of material, which covers all of the filtration apertures 85. In another embodiment the filter 87 is formed of at least two parts, wherein each part covers one or more of the filtration apertures. The filter 87 is preferably made of a material with a high wet strength, for example a non-woven fibre material of polyester. Other materials which may be used include a water-impermeable cellulosic material, such as a cellulosic material comprising woven paper fibres. The woven paper fibres may be admixed with fibres of polypropylene, polyvinyl chloride and/or polyethylene. The incorporation of these plastic materials into the cellulosic material renders the cellulosic material heat-sealable. The filter 87 may also be treated or coated with a material which is activated by heat and/or pressure so that it can be sealed to the annular support member 80 in this way.

The funnel 81 comprises a first tubular element 88 which extends from the inner periphery of the inner annular hub 82. A frustro-conical element 89 extends from the bottom of the first tubular element 88 and an annular plate 92 extends inwardly from the narrower periphery of the frustro-conical element 89. A second tubular element 90 extends from the inside edge of the annular plate 92. A third tubular element 91 extends from an outer surface of the frustro-conical element 89 and encircles the second tubular element 90 defining an annular gap therebetween. In one embodiment the second tubular element 90 has a lesser height than, or does not extend as far as, the third tubular element 91. A major opening 93 is formed by the free end of the second tubular element 90 and a minor opening 94 is formed by the free end of the second tubular element 90.

The inner member 60 is preferably formed as a single part. However, in other embodiments the inner member 60 may be formed from several parts joined together in a similar manner to that discussed above in respect of the reusable cap 12.

The capsule 11 may be provided with means for entraining air into the beverage, for example in the form of an eductor. As used herein, the term eductor refers to the use of a flow constriction in the form of an aperture, or similar structure, to form a jet of beverage, the aperture being located in the beverage flow path upstream of an air inlet and an expansion chamber, said aperture being arranged to produce a jet of beverage which jets into the expansion chamber to produce a low pressure zone in the vicinity of the air inlet which causes air to be drawn through the air inlet and to become entrained in the beverage stream as a plurality of bubbles. The flow constriction may be arranged between channel 95 and the minor opening 94 and the air inlet is arranged in the second tubular element 92.

During assembly of the disposable capsule 11 the inner member 60 is placed inside of the outer member 61, as shown in Figures 9 and 10. The inner member 60 is preferably ultrasonically welded to the outer member 61, or there may be an interference fit between the two. The recessed section 69 is located inside the funnel 81, with the top edges of the support ribs 84 resting against the inside surface of the top wall 65. An outlet channel 95 is thus formed between the inner and outer member 60, 61 which extends from between the top wall 65 and the outer rim 86, and between the funnel 81 and recessed section 69, which communicates with the tubular element 90 and fluid is able to exit the cartridge 10 via the minor opening 94. This space is formed as the outer diameters of the recessed section 69 are less than the inner diameters of the funnel 81.

The ingredients are packed into the disposable capsule 11 in the interior 68 defined by the annular side wall 66, the filter 87 and the funnel 81. Any type of beverage ingredients may be used, such as coffee, tea or chocolate. The cartridge 10 may also be used for the preparation of certain types of food products, such as custard and other milk based desserts and the like.

The brewing chamber is closed off by the membrane 63. The membrane 63 is preferably annular. An outer periphery of the membrane 63 is ultrasonically welded to the flange 74, and an inner periphery, or a part of the membrane 63 adjacent to the inner periphery, is ultrasonically welded to the mouth of the third tubular element 91, which defined the major opening 93. Other forms of pressure or heat welding may be used instead of ultrasonic welding. The membrane 63 is preferably formed from an impermeable material capable of forming a thin film, such as polyethylene terephthalate (PET) or polypropylene. The membrane 63 may be opaque, transparent or translucent. The membrane 63 comprises a plurality of apertures 96 which allow fluid to pass through the membrane 63 into the brewing chamber in the interior 68. In one embodiment, the apertures 96 are arranged in a circle, although there may be a number of circles. Alternatively, the membrane is semi-permeable.

To complete assembly of the disposable capsule 11, a removable lid 62 is attached. The removable lid 62 comprises a cover portion 77 and a handle 76. The cover portion 77 is substantially circular and is ultrasonically, heat or pressure welded to the underside of the flange 74 of the disposable capsule 11 thereby covering the open bottom 67 of the outer member 61. The handle 76 extends from the cover portion 77 and enables the removable lid 62 to be removed by peeling the cover portion 77 from the flange 74. The cover portion 77 and handle 76 are preferably formed from a single thin and impermeable sheet. A suitable material for forming the sheet is a flexible laminate material including oxygen barrier layers to protect the freshness of the beverage ingredients. The removable lid 62 thus seals the interior 68 of the outer member 61 from the outside environment to maintain the freshness of the ingredients inside the disposable capsule 11.

The reusable cap 12 and disposable capsule 11, other than the ring seals 48, 49, filter 87, removable lid 62 and membrane 63, are preferably formed from high density polyethylene, polypropylene, polystyrene, polyester, or a laminate of two or more of these materials. A suitable polypropylene is the range of polymers available from DSM UK Limited (Redditch, United Kingdom). Alternatively the reusable cap 12 and disposable capsule 11 may be made from a polymeric material, preferably a biodegradable polymer. Examples of suitable materials include degradable polyethylene, biodegradable polyester amide, poly lactic acids, starch-based polymers, cellulose derivatives and polypeptides The reusable cap 12 and disposable capsule 11 may be opaque, transparent or translucent and may be rigid or semi-rigid. In one embodiment the process used to manufacture the reusable cap 12 and disposable capsule 11 is injection moulding.

Before use, the removable lid 62 must be removed from the disposable capsule

11. At this point the ingredients inside the disposable capsule 11 are exposed to air, which flows in through the membrane 63. As shown in Figures 1 and 13, the reusable cap 12 is placed on the disposable capsule 11. The capsule 11 and reusable cap 12 are positioned such that the capsule interlocking means 75 are aligned with the spaces between the cap interlocking means 41. The disposable capsule 11 is then moved axially relative to the reusable cap 12 such that the capsule interlocking means 75 bypass the cap interlocking means 41 and the capsule flange 74 is located against the major ring seal 49 and the lower edge of the third tubular element 91 located against the minor ring seal 48. The flange 74 is located within the inner circumference of the annular wall 21. The disposable capsule 11 is then releasably sealed to the reusable cap 11 by engaging the interlocking means 75, 41. The disposable capsule 11 and reusable cap 12 are pressed together and one or both of them are rotated such that the capsule interlocking means 75 on the disposable capsule 11 engage with the cap interlocking means 41 on the reusable cap 12. The stops 42 prevent the disposable capsule 12 from being over rotated to the extent that the cap interlocking means 41,75 fail to engage.

Once the cartridge 10 has been used to form a beverage, the disposable capsule 11 may be released from the reusable cap 12 by rotating one or both of the disposable capsule 11 and the reusable cap 12 such that the interlocking means disengage, then pulling the disposable capsule 11 and reusable cap 12 apart.

Figures 14 to 18 illustrate further embodiments of cartridge 10 according to the present disclosure. In the following description only the differences between the cartridge of the further embodiments and the cartridge as described above will be described in detail. In all other respects, the cartridge may be as described above. Like reference numerals have been used for like features.

In a second embodiment of the disclosure, the cartridge is adapted for engagement of the disposable capsule 11 and reusable cap 12 in a two-stage process. In the embodiment shown in Figures 14a to 14d, capsule interlocking means 175 and cap interlocking means 141 are adapted to be releasably engaged by pressing the disposable capsule 11 and reusable cap 12 together axially such that the capsule interlocking means 175 slide over and then engage the cap interlocking means 141.

Latching means 148 is provided on the reusable cap 12 for latching the reusable cap 12 and disposable capsule 11 together before the interlocking means are engaged. In the embodiment shown in Figure 14a, the latching means 148 comprise second inwardly directed protrusions arranged axially between the cap interlocking means 141 and the rim of the annular wall 21. The second inwardly directed protrusions are in the form of one or more curved bars extending longitudinally around the inner side of the annular wall 21.

Stops 142 are provided in the form of one or more curved bars extending longitudinally around the inner side of the annular wall 21. The stops 142 are arranged axially between the latching means 148 and the rim of the annular wall 21. The stops 142 are axially spaced from the latching means 148, are aligned with the spaces between the latching means 148 and are separated by spaces sized to allow cap interlocking means 141 of the reusable capsule 12 to pass between the protrusions, such that a labyrinthine path on the annular wall 21 is formed through which the capsule interlocking means 175 may pass, as described below.

As shown in Figure 14b, the disposable capsule 11 and reusable cap 12 may be releasably engaged by pressing the disposable capsule 11 and reusable cap 12 together in a two-stage process. In a first stage (A), the capsule 11 and reusable cap 12 are positioned such that the capsule interlocking means 175 are aligned above the latching means 141. The capsule 11 is then moved axially relative to the capsule 12 such that the capsule interlocking means 175 slide over and then engage the latching means 141. Ina second stage capsule 11 is then moved axially relative to the capsule 12 such that the capsule interlocking means 175 slide over and then engage the cap interlocking means 41.

The capsule interlocking means 175 preferably comprise an angled lower surface and an upper surface substantially perpendicular to the capsule wall. The first and second inwardly directed protrusions preferably comprise an angled upper surface and a lower surface substantially perpendicular to the annular wall 21, to facilitate the capsule interlocking means sliding over the protrusions before being engaged by them. The first inwardly directed protrusions may protrude a shorter distance from the annular wall 21 and/or be smaller in the axial direction and/or be more flexible than the second inwardly directed protrusions such that less force is required to carry out the first stage of the process than is required to carry out the second stage of the process. Preferably, a user may interlock the cap interlocking means 141 on the reusable cap 12 with the capsule interlocking means 175 by hand. The cartridge 10 may then be placed in the cartridge mount of a beverage machine. The beverage machine may be adapted to compress the disposable capsule 11 and reusable cap 12 axially together such that the interlocking means 141, 175 interlock, sealing the cartridge, as indicated by the arrow (B) in Figures 14a and 14b.

The use of a two-stage engagement process allows for simple assembly by hand by the user, who is not required to assemble the components tightly enough to form a seal, while allowing for an effective seal to be produced by using the beverage machine clamping mechanism to form the seal.

As shown in Figure 14c, once the cartridge 10 has been used to form a beverage, the disposable capsule 11 is released from the reusable cap 12 by rotating one or both of the disposable capsule 11 and the reusable cap 12 such that the capsule interlocking means 175 are aligned with the spaces between the cap interlocking means 141 (as shown by arrow C). The capsule 11 is then moved axially relative to the capsule 12 such that the capsule interlocking means 175 bypass the cap interlocking means 141 and the latching means 148 and abut the stops 142 (as shown by arrow D). One or both of the disposable capsule 11 and the reusable cap 12 are then rotated relative to the other until the capsule interlocking means 175 are aligned with the spaces between the stops 142 (as shown by arrow E). The capsule 11 is then moved axially relative to the reusable cap 12 (as shown by arrow F) such that the capsule interlocking means 175 bypass the stops and the capsule 11 is released from the reusable cap 12.

Optionally, the reusable cap 12 may comprise a second annular wall 121 arranged inside the first annular wall such that, on assembly of the cartridge, the capsule interlocking means 175 extends downwards from the disposable capsule 11 and passes between the first and second annular walls 21, 121. The second annular wall 121 retains the capsule interlocking means in a radial direction such that the capsule interlocking means 75 is held in engagement with the cap interlocking means 141, as shown in Figure 14d.

In a third embodiment, the cartridge comprises a disposable capsule 211 and a reusable cap 212. As shown in Figure 15a the reusable cap 212 comprises a base 20 and an arcuate wall 221. The base 20 may be substantially as described above. The arcuate wall 221 is located on the annular ring portion 24 and may be concentric with the outlet aperture 27. The arcuate wall 221 comprises an upstanding portion having a lateral flange extending around the inside of the arc and spaced from the surface of the base 20 to form a wall recess 237.

Capsule interlocking means 275 comprises a capsule flange extending around all or part of the disposable capsule 211. The capsule flange has a thickness which is less than the spacing between the lateral flange of arcuate wall 221 and the surface of the base 20 and has an outer diameter which is approximately equal to or smaller than the inside diameter of the arcuate wall 221, such that it fits into recess 237.

The disposable capsule 211 may therefore be placed on the surface of the base 20 and moved laterally until the capsule flange engages with the arcuate wall 221. Preferably, the arcuate wall 221 has an arc of 90 to 180 degrees such that lateral movement of the disposable capsule 211 relative to the reusable cap (when compared to the direction of insertion as shown in Figure 15) is constrained by the arcuate wall 221.

The base 20 further comprises cap interlocking means 241 for engagement with capsule interlocking means 275. Cap interlocking means 241 may comprise a protrusion extending from the surface of the base 20. The illustrated cap interlocking means 241 comprises a wedge, however other forms of protrusion may be used, for example a cuboid or curved protrusion or a raised flap. The protrusion is arranged such that when the disposable capsule 211 and reusable cap 212 are conjoined, the protrusion abuts the disposable capsule 211, preferably the capsule flange. The abutting surface of the protrusion may be spaced from a distal point of the arcuate wall by a distance corresponding to the diameter of the disposable capsule 211. Alternatively, the protrusion may be positioned to engage with an engagement features on an adjacent face of the disposable capsule 211.

Preferably, the protrusion may be resilient in order to facilitate engagement and disengagement of the disposable capsule 211 and reusable cap 212. Alternatively, the base 20 may be sufficiently resilient to accommodate engagement of the disposable capsule 211 with the cap interlocking means 241.

The disposable capsule 211 and reusable cap 212 may therefore be releasably engaged by pressing the disposable capsule 211 and reusable cap 212 together laterally until the capsule interlocking means passes under the lateral flange of the arcuate wall 221 to abut an inner surface of the arcuate wall 221. The base and/or protrusion may resiliently to deform to accommodate engagement of the disposable capsule 211 and the reusable cap 212. Once the disposable capsule 211 is in position, the resilient component will return to its original shape. The protrusion thereby engages the disposable capsule 211.

In this embodiment, the brewer is inserted into the holder in a direction substantially perpendicular to the direction of clamping of the brewing machine such that, in use, there is maximum resistance to the separation of the parts as the pressure in the brewing machine increases.

In addition, this lateral attachment method may allow reusable cap 212 to be attached to the disposable capsule 11 while the latter is in its packaging, thereby minimising the possibility of damage caused by direct handling of the disposable capsule 11, as shown in Figure 15b.

In a fourth embodiment, the cartridge comprises disposable capsule 311 and a reusable cap 312, the reusable cap 312 being formed from two parts as shown in Figure 16. The reusable cap 312 is illustrated in Figure 16 and comprises a base 320 with an integral annular wall 321 and a separately formed retaining element 352. The retaining element 352 and base 320 are provided with cap interlocking means 341 for releasably interlocking the retaining element 352 and base 320.

The base 320 may be substantially as described above. The annular wall 321 extends upward from the base 320. The annular wall 321 is preferably integrally formed with the base 320 but could alternatively be attached thereto, as described in the first embodiment.

The retaining element 352 comprises an annular portion 350 having an outer diameter which is smaller than an inner diameter of annular wall 321. In use, the annular portion 350 forms an outer wall of the cartridge. The annular portion 350 has an inner diameter larger than the outer diameter of the annular side wall 66 of disposable capsule 311. The annular portion 350 extends from a flange-abutting portion 353 to an inward lateral flange 351.

Preferably the height of the annular portion 350 is substantially the same as the height of the side wall 66 . The inward lateral flange 351 extends towards the centre of the annulus and has an innermost diameter which is smaller than the outer diameter of the annular side wall 66 of disposable capsule 311 such that, in use, the disposable capsule 311 can be at least partially enclosed and thereby retained between the retaining element 352 and the base 320. Alternatively, the height of the annular portion 350 may be substantially the same as the height of the flange 74 of the disposable capsule 311 and the inward lateral flange 351 may extend towards the centre of the annulus and have an innermost diameter which is smaller than the outer diameter of the flange 66 such that the flange 74 is at least partially enclosed and the disposable capsule 311 is thereby retained between the retaining element 352 and the base 320.

The external surface of the annular portion 350 and the inner surface of the annular wall 321 comprise corresponding cap interlocking means 341 for releasably attaching the annular portion 350 to the base 320. The cap interlocking means 341 may comprise, for example, screw threads, a bayonet fitting or one or more interlocking protrusions.

The disposable capsule 311 comprises capsule interlocking means 375. The capsule interlocking means 375 may comprise a continuous or intermittent flange arranged around the periphery of the disposable capsule 311. A recess may be provided in the base 20 to receive the flange of the interlocking means 375.

To assemble of the cartridge the disposable capsule 311 may be placed on the base 320 inside the annular wall 321, preferably in the recess as shown in Figure 16. The annular portion 350 is then placed over the capsule 12 such that the flange-abutting portion 353 contacts the flange of the capsule interlocking means 375. The cap interlocking means 341 are then releasably engaged by rotating or pressing the annular portion 350 relative to the base such that the disposable capsule 311 is retained between the flange 351 of the annular portion 350 and the base 320 to form the cartridge.

The reusable cap 312 may have outer dimensions adapted to fit the large brew heads of existing beverage machines, thereby allowing use of smaller, cheaper, lower carbon footprint capsules in existing beverage machines. The waste from the single use disposable capsule 311 is limited by this smaller size and it is not necessary to use a complete new brewing system, thereby reducing the number of brewing machines which are scrapped.

Optionally, the flange of the capsule interlocking means 375 may form a plate extending inwards for enclosing or substantially enclosing the disposable capsule 311 when the cartridge is assembled. In use, this total or near-total coverage of the disposable capsule 311 provides a thermal barrier between the contents of the disposable capsule 311 and the environment, improving heat retention in the disposable capsule 311. Optionally, the plate may comprise a recessed portion adapted to nest within the recessed portion 69 of the disposable capsule 311.

Optionally, as shown in Figure 19a, the cap interlocking means 341 may comprise one or more outwardly directed protrusions extending longitudinally around the outer edge of the annular portion 350 and having the same form as capsule interlocking means 175 of the second embodiment. The cap interlocking means 341 further comprise first and second inwardly directed protrusions of the same form as latching means 148 and cap interlocking means 141 as described for the second embodiment, the first and second inwardly directed protrusions being arranged on the inside of annular wall 321. The cap interlocking means 341 serve to latch and interlock the retaining element 352 and base 320 by the same method used in the second embodiment, as shown in Figures 20a and 20b. For clarity, the disposable capsule 311 is omitted from Figures 20a and 20b.

In any of the above embodiments, the base may comprise sealing means 354 for forming a seal between the second tubular element 91 and the periphery of the outlet aperture 27.

Optionally, as shown in Figure 17 in any one of the embodiments described above, the second tubular element 90 may be absent from the inner member 60 of the disposable capsule 11 and annular plate 92 may comprise an opening 494 as shown in Figure 17. In this case, the base 20 comprises a cap tubular element 491 extending from the rim of outlet aperture 27. A cap annular plate 492 extends inwardly from the cap tubular element 491. A second cap tubular element 490 extends from the inside edge of the annular plate 492 towards the outlet aperture 27 such that the cap tubular element 491 encircles the second cap tubular element 490 defining an annular gap therebetween. Minor opening 94 is formed by the free end of the second cap tubular element 490. A seal 454 is arranged between the cap annular plate 492 and annular plate 92. The second cap tubular element 490 may optionally also extend away from the outlet aperture such that, on assembly of the capsule 411, an upper end of the second cap tubular element abuts the recessed section 69 of the outer member 61. An eductor may be formed by providing a flow constriction in the form of an aperture, or similar structure, between the reusable cap 12 and disposable capsule 11.

The formation of an eductor between the reusable cap 12 and disposable capsule 11 has the benefit of providing stable eductor geometry and so more repeatable foam generation/better user experience.

As shown in Figure 18, the eductor comprises an aperture 496 delimited by an interface between reusable cap 12 and disposable capsule 11. A shoulder of recessed section 69 of the outer member 61 bears against the upper edge of the second cap tubular element 494. An interface zone 495 is thus formed between the reusable cap 12 and the disposable capsule 11 comprising a face seal 454 between the outer member 61 and the second cap tubular element 494 which extends around nearly the whole circumference of the cartridge 1. The seal between the outer member 61 and the second cap tubular element 494 is not fluid-tight though since a slot 496 in the upper edge of the second cap tubular element 494 extends through the second cap tubular element 494 and downwardly to a point marginally below the shoulder. Consequently the interface fit between the outer member 61 and the second cap tubular element 494 transforms the slot 496 into an aperture, as most clearly shown in Figure 18, providing gas and liquid communication between the annular channel 95 and the minor opening 94. The aperture is typically 0.64 mm wide by 0.69 mm long.

After assembly, the cartridge may be placed in the cartridge mount of the machine for preparing food or beverage products. A fluid injection means of the machine will form a seal with the fluid inlet arrangement 26 and an outlet means of the machine will form a seal with the outlet aperture 27 or minor opening 94. If the machine from EPB-1715779 is used, the inlet and outlet piercers form the fluid injection means and the outlet means. The seal is formed by the compression of a rubber annular seal at the base of the piercers by the underside of the reusable cap 12.

During the preparation cycle, a fluid (such as water or milk) is injected into the cartridge 10 via the fluid inlet arrangement 26 by the fluid injection means. The fluid then flows out of cavity inlet apertures 45 and fills the inlet cavity 31. As more fluid is injected, the level of fluid in the inlet cavity 31 rises and the fluid eventually enters the disposable capsule 11 through the membrane 63. The fluid mixes with the ingredients inside the disposable capsule 11 to enable the preparation process to take place and to form the beverage or food product. Under sufficient pressure, the prepared beverage or food product flows through the filter 87, via the outlet channel 95, out of the minor opening 94 and out of the outlet aperture 27. The prepared beverage is thus delivered to the beverage outlet means or directly into a receptacle, such as a cup.

Once the beverage has been dispensed, the cartridge 10 is removed from the machine and the disposable capsule 11 and reusable cap 12 separated. The disposable capsule 11 is disposed of, and the reusable cap 12 may be kept for several further uses.

As a result, in the cartridge 10 of the present disclosure the amount of packaging material used per serving of a beverage or food product is reduced, whilst maintaining the suitability of the cartridge for use with known machines. It has been found that the volume of material used in the cartridges 10 is up to 50% less than that used in the cartridges disclosed in EP-B-1715779.

It should also be appreciated that use of the terms vertical, horizontal and lateral throughout this specification are in the context of the illustrated embodiments. Use of these terms should not be taken to mean that the cartridge 10 is only useable in one (or a specific limited number) of orientations. Rather, the cartridge 10 may be used in any orientation. Vertical, horizontal and lateral are thus used as relative rather than absolute terms.

Claims

CLAIMS:

1. A kit for the self-assembly of a cartridge for use in a machine for preparing food or beverage products, the kit comprising a reusable cap and a disposable capsule; wherein the reusable cap is configured to locate the cartridge in the machine; and the disposable capsule is configured to hold beverage ingredients;

wherein the reusable cap and disposable capsule are releasably engagable to form the cartridge.

2. A kit as claimed in claim 1 wherein the reusable cap and the disposable capsule are configured such that a means for entraining air into the beverage is formed between the reusable cap and the disposable capsule when the reusable cap and disposable capsule are engaged.

3. A kit as claimed in claim 2 wherein means for entraining air into the beverage comprises a slot formed in the reusable cap for co-operation with a corresponding part of the disposable capsule to form an eductor.

4. A kit as claimed in any of claims 1 to 3 wherein the reusable cap comprises a base and a retaining element, wherein the base is configured to releasably interlock with the retaining element to retain at least a portion of the disposable capsule between the base and the retaining element in use.

5. A kit as claimed in claim 4 wherein the base and the retaining element are provided with complementary interlocking means.

6. A kit as claimed in claim 1 or claim 2 in which the disposable capsule and reusable cap are provided with complementary interlocking means.

7. A kit as claimed in claim 5 or claim 6 wherein the complementary interlocking means comprise a screw thread or a bayonet element or a twist-to-lock element.

8. A kit as claimed in any of claims 5 to 7 wherein the complementary interlocking means comprise a releasable push-fit element or releasable latch element.

9. A kit as claimed in claim 8 wherein the reusable cap and disposable capsule are configured to be slidably engagable by lateral movement of one or both of the disposable capsule and the reusable cap relative to the other of the disposable capsule and the reusable cap.

10. A reusable cap for use in the kit as claimed in any preceding claim.

11. The reusable cap as claimed in claim 10, wherein the reusable cap comprises a slot for co-operation with a corresponding part of a disposable capsule to form an eductor.

12. The reusable cap as claimed in claim 10 or claim 11 comprising interlocking means for interlocking with a disposable capsule.

13. The reusable cap as claimed in claim 10 or claim 11 comprising base and a retaining element, wherein the base is configured to releasably interlock with the retaining element for retaining a disposable capsule between the base and the retaining element in use.

14. The reusable cap as claimed in claim 13 wherein the base and the retaining element are provided with complementary interlocking means.

15. The reusable cap as claimed in claim 12 or claim 14 wherein the complementary interlocking means comprise a screw thread or a bayonet element or a twist-to-lock element.

16. The reusable cap as claimed in claim 12, claim 14 or claim 15 wherein the complementary interlocking means comprise a releasable push-fit element or releasable latch element.

17. The reusable cap as claimed in any of claims 10 to 16 having an outer periphery the shape of which is configured to assist in the location of the cartridge in a machine.

18. The reusable cap as claimed in any of claims 10 to 17 having a base which is provided with recesses which are configured to assist in the location of the cartridge in a machine.

19. The reusable cap as claimed in any of claims 10 to 18 further comprising a fluid inlet configured for communication with fluid injection means of a machine in which it is located.

20. The reusable cap as claimed in any of claims 10 to 19 further comprising an outlet for the delivery of a prepared food or beverage product.

21. The reusable cap as claimed in any of claims 10 to 20 further comprising a cavity which is open when the disposable capsule is not engaged with the reusable cap.

22. The reusable cap as claimed in claim 21 further comprising means defining a fluid flow path from the fluid inlet to the cavity.

23. The reusable cap as claimed in any of claims 10 to 22 further comprising sealing means against which members of the disposable capsule abut when the reusable cap and disposable capsule are engaged.

24. A disposable capsule for use in the kit as claimed in any of claims 1 to 9 comprising a chamber containing at least one beverage or food ingredient.

25. The disposable capsule as claimed in claim 24 wherein the chamber is sealed with a removable lid which must be removed before engagement of the disposable capsule and the reusable cap.

26. The disposable capsule as claimed in claim 24 or claim 25 wherein a cap inlet cavity communicates with the chamber when the disposable capsule and reusable cap are engaged.

27. The disposable capsule as claimed in any one of claims 24 to 26 further comprising means defining a fluid flow path from the chamber to an outlet which, when the disposable capsule and reusable cap are engaged, communicates with a cap outlet aperture.

28. A cartridge for use in a machine for preparing food or beverage products

5 comprising the reusable cap as claimed in any one of claims 10 to 23 engaged with the disposable capsule of any one of claims 23 to 26.

29. A method of dispensing a beverage or food product during an operating cycle from a cartridge assembled from a kit claimed in any of claims 1 to 9, the method

10 comprising the steps of engaging the reusable cap and the disposable capsule, injecting a liquid through a fluid inlet in the reusable cap, passing the liquid through the disposable capsule and dispensing the beverage or food product out of an outlet in the reusable cap and into a receptacle.

15

30. A beverage or food dispensing system comprising a cartridge assembled from a kit as claimed in any of claims 1 to 9 and a beverage or food dispensing machine adapted to receive the cartridge and to dispense a beverage or food product therefrom by the addition of a liquid.