Patent Publication Number: US-2017362020-A1

Title: Capsule for preparing consummable product

Description:
FIELD 
     This specification relates to consumable products and in particular to capsules for preparing a consumable product. 
     BACKGROUND 
     The following background discussion is not an admission that anything discussed below is citable as prior art or common general knowledge. The documents listed below are incorporated herein in their entirety by this reference to them. 
     Single serve capsules for use in machines to prepare a desired consumable product are becoming increasingly popular. Such capsules come in a variety of formats most typically for producing beverages such as espresso coffee, drip coffee, tea, hot chocolate or soup broth. 
     Capsule machines typically include an injection system for injecting a fluid, such as hot water, into a capsule for mixing with ingredients disposed within the capsule. A dispensing system is also provided to dispense the prepared product from the capsule for delivery to a receptacle such as a user&#39;s cup or bowl. The dispensing system may for instance comprise a hollow probe that is adapted to pierce the capsule and allow product to flow through or around the probe from the capsule for delivery to a desired receptacle. 
     A problem with conventional single serve capsules and capsule machines is that they are not adapted for use with insoluble consumable ingredients. Such ingredients will not easily flow through conventional dispensing systems such as those with hollow narrow diameter probes in order that they may be deposited into the desired receptacle for consumption by a user. For example, vegetables and noodles for a soup product will not flow through a conventional hollow probe dispensing system for a capsule machine. 
     Another problem with conventional single serve capsules is that they are not adapted for separating ingredients within the capsule in a cost effective manner to meet regulatory standards or other product requirements. For example, it may be desirable to prepare a product from two or more ingredients that must be kept separate from one another within the capsule until the preparation stage. The ingredients may include dry ingredients and wet ingredients that may not be mixed until the preparation stage. Or the ingredients may include an active ingredient that reacts in the presence of another ingredient. Or the ingredients may include an additive that must be separated from other ingredients and be delivered directly into a cup for improving efficacy. 
     Another problem with conventional single serve capsules is that they are not adapted for dispensing product to a desired receptacle without exposing portions of the capsule machine to contamination by the dispensed product. This is a problem when the residue from the dispensed product comes into contact with subsequent products prepared with the capsule machine. This can impact flavors and can also present a health risk when the dispensed product contains ingredients that may be harmful to others (such as regulated drugs, alcohol or ingredients that may be an allergy risk such as a peanut allergy). 
     There is a need for an improved capsule for use in a capsule machine that addresses one or more problems with conventional capsules such as those listed above. 
     SUMMARY 
     In one aspect the invention provides a capsule, for use in a machine for preparing consumable products from capsules, said capsule comprising: 
     a body defining an interior space with an opening at one location and an aperture at another location; 
     ingredients disposed in said interior space for preparing a desired product; 
     a cover disposed over said opening; and 
     an aperture cover disposed over said aperture, said aperture cover being adapted to open at least partially during use of the capsule in the machine to permit the consumable product to be dispensed. 
     In another aspect the invention provides a capsule, for use in a machine for preparing consumable products from capsules, said capsule comprising: 
     a body having a side wall extending from an end wall to an opening to define an interior space, said opening being surrounded by a flange; 
     ingredients disposed in said interior space for preparing a desired product; 
     a cover disposed over said opening; 
     an aperture defined in said end wall; 
     an aperture cover disposed on said end wall to cover said aperture, said aperture cover being adapted to open at least partially during use of the capsule in the machine to permit the consumable product to be dispensed. 
     Other aspects and features of the teachings disclosed herein will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific examples of the specification. 
    
    
     
       DRAWINGS 
       The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification and are not intended to limit the scope of what is taught in any way. For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. 
         FIG. 1  is a schematic view of a capsule in accordance with the present invention being loaded into a capsule machine for preparing a consumable product; 
         FIG. 2  is a vertical sectional view of another embodiment of capsule in accordance with the present invention; 
         FIG. 3( a )  is a vertical sectional view of another embodiment of capsule in accordance with the present invention, the capsule having an exit nozzle disposed in a retracted position; 
         FIG. 3( b )  is a vertical sectional view of the capsule as shown in  FIG. 3( a ) , with the exit nozzle disposed in an extended position; 
         FIG. 4( a )  is a vertical sectional view of another embodiment of capsule in accordance with the present invention; 
         FIG. 4( b )  is a perspective view of a conical insert for use with the capsule shown in  FIG. 4( a ) ; 
         FIG. 5  is a vertical sectional view of another embodiment of capsule in accordance with the present invention; 
         FIG. 6  is a vertical sectional view of another embodiment of capsule in accordance with the present invention; 
         FIG. 7  is a schematic enlarged sectional view of the dispensing system for the capsule shown in  FIG. 6 ; 
         FIG. 8  is a vertical sectional view of another embodiment of capsule in accordance with the present invention; 
         FIG. 9( a )  is a bottom view of the capsule of  FIG. 8 ; 
         FIG. 9( b )  is a bottom view of an alternate embodiment of the capsule of  FIG. 8 ; 
         FIG. 9( c )  is a bottom view of an alternate embodiment of the capsule of  FIG. 8 ; 
         FIG. 10  is a side perspective view of another embodiment of capsule in accordance with the present invention; 
         FIG. 11( a )  is a top view of the capsule of  FIG. 10  with the cover, filter and ingredients removed; 
         FIG. 11( b )  is a top view of an alternative embodiment of the capsule of  FIG. 10  with the cover, filter and ingredients removed; 
         FIG. 12  is a sectional view of the capsule of  FIG. 10  along lines  12 - 12 ; 
         FIG. 13  is a sectional view of the capsule of  FIG. 10  along lines  13 - 13 ; and 
         FIG. 14  is a bottom view of the capsule of  FIG. 10 . 
     
    
    
     DESCRIPTION OF VARIOUS EMBODIMENTS 
     Various apparatuses or methods will be described below to provide examples of the claimed invention. The claimed invention is not limited to apparatuses or methods having all of the features of any one apparatus or method described below or to features common to multiple or all of the apparatuses described below. The claimed invention may reside in a combination or sub-combination of the apparatus elements or method steps described below. It is possible that an apparatus or method described below is not an example of the claimed invention. The applicant(s), inventor(s) and/or owner(s) reserve all rights in any invention disclosed in an apparatus or method described below that is not claimed in this document and do not abandon, disclaim or dedicate to the public any such invention by its disclosure in this document. 
     A single serve capsule in accordance with the present invention is shown generally at  10  in the figures. Capsule  10  includes a body  12 , filter  14  (when required), ingredients  16  and cover  18 . 
     Ingredients  16  may include soluble and insoluble ingredients. Insoluble ingredients may include consumable ingredients  16   a  (ingredients, such as noodles and dried vegetables, that are intended to be consumed as part of the prepared product) and non-consumable ingredients  16   b  (ingredients, such as tea leaves, coffee grounds, herbs or other flavoring ingredients, that are not intended to be consumed as part of the prepared product). Ingredients  16  may include active ingredients (eg foaming agents), natural health additives, regulated drugs, alcohol or other desired ingredients. 
     Capsule  10  is sized and configured for use in a machine  20  that is adapted for preparing a product from capsule  10 . Capsule may be formed in any shape that is adapted to fit within a corresponding capsule chamber disposed in machine  20 . Machine  20  may include an injection system  22  for injecting a fluid, typically heated water, into the capsule for mixing with ingredients  16 . Injection system  22  may include a nozzle  22   a  disposed on machine  20  that is adapted to pierce cover  18  to inject fluid into capsule  10 . Injection system  22  may alternatively have at least one component disposed on capsule  10 , such as on cover  18 , and adapted to pierce body  12  and interact with machine  20  to inject fluid into capsule  10 . 
     Machine may also include a dispensing system  24  for dispensing product from capsule  10  into a desired receptacle  26  such as a bowl or cup. Dispensing system  24  may include a probe  24   a,  such as a hollow probe, that is adapted to pierce capsule  10  to dispense a prepared product from capsule  10 . 
     Probe  24   a  may be adapted to pierce end wall  32  of capsule  10 . Dispensing system  24  may further include a collection chamber  24   b  and exit port  24   c,  downstream from probe  24   a  for collecting and dispensing prepared product into receptacle  26 . 
     Probe  24   a  may alternatively be adapted to pierce cover  18  of capsule  10  at a location that allows outflow of product from capsule  10 . In this instance, capsule  10  is disposed in machine  20  at an angle that allows outflow of product through or around probe  24   a  (not shown). One example of a machine that includes such a dispensing system is the Keurig Vue™ system. Another example is the Keurig 2.0™ system which includes both a bottom probe adapted to pierce the cover of one form of capsule and a top probe adapted to pierce an end wall of a different form of capsule. 
     Capsule  10  may be configured to avoid interaction with hollow probe  24   a  for use in cases where a conventional hollow probe  24   a  is not adapted for dispensing insoluble consumable ingredients  16   a.  Such ingredients  16   a  may become clogged within the small diameter channel defined in hollow probe  24   a . It may also be desirable to avoid interaction with probe  24   a  for other reasons, for instance in order to eliminate flavor transfer or cross-contamination between beverages of different types. Alternatively, machine  20  may be adapted to enable probe  24   a  to be moved away from a position where it may pierce end wall  32 . An example of such a machine is the Keurig 2.0™ system. 
     Body  12  of capsule  10  includes a sidewall  30  and an end wall  32  together defining an interior space  34 . Sidewall  30  has a first portion  30   a  and a second portion  30   b.  Second portion  30   b  is configured to avoid contact with dispensing system  24  when capsule is disposed in machine  20 . Second portion may thus taper inwardly from first portion  30   a  to end wall  32  sufficiently to avoid contact with dispensing system  24 . 
     An opening  36  is defined at one end of body  12  and a flange  38  extends around the perimeter of opening  36 . 
     Filter  14  is adapted to be disposed within body  12  to define at least one ingredients chamber within interior space  34  for receiving one or more ingredients  16  and in particular non-consumable ingredients  16   b.  Filter  14  may be secured to flange  38  or to an interior surface of capsule  10  (such as to sidewall  30 ). Capsule  10  may be provided without filter  14  in instances where ingredients are soluble or where it is desired that ingredients  16  are dispensed together with fluid into receptacle  26  (as shown in  FIG. 2 ). 
     Cover  18  is disposed over opening  36  and secured to body  12  such as by sealing cover  18  directly to flange  38  or indirectly with a portion of filter  14  located between. 
     An aperture  40  is defined in end wall  32  for dispensing product from capsule. Aperture  40  is sized to allow product including consumable ingredients  16   a  to pass through aperture  40  without clogging. Preferably aperture  40  has a diameter in the range of 5-50 mm, more preferably 10-30 mm and most preferably 15-25 mm. 
     Second portion  30   b  of side wall  30  tapers inwardly from first portion  30   a  to aperture  40 . Second portion  30   b  thus directs product within capsule  10 , including consumable insoluble ingredients  16   a,  toward aperture  40 . 
     A soluble closure  42  is provided to close aperture  40  to prevent consumable ingredients  16   a  from passing through aperture  40  until fluid is injected into capsule. Soluble closure  42  may be formed of any food safe (edible) soluble material that is suitable for preventing ingredients from passing through aperture  40  until the desired time. 
     Soluble closure  42  may for example be in the form of a membrane (as shown in  FIGS. 1, 2 and 4 ) that covers aperture  40  or in the form of a plug (as shown in  FIGS. 3( a ) and 3( b ) ) that is disposed within aperture  40 . When closure  42  is in the form of a membrane it may be sealed to an interior surface of capsule  10  around the perimeter of aperture  40  using suitable sealing materials such as polyethylene or polypropylene. When closure  42  is in the form of a plug it may be sized to fit snugly within aperture  40  with or without the aid of a similar sealing material. A plug is best suited for use when aperture  40  comprises an elongate passage. 
     Closure  42  is adapted to dissolve upon exposure to fluid within a predetermined time. In some instances, it is preferable that there is a delay in the dissolution of closure  42  in order to allow the fluid and ingredients  16  to mix and steep to extract flavor or functional components prior to dispensing product from capsule  10 . This is particularly desirable when certain ingredients are non-consumable insoluble ingredients contained within filter  14 . In such instances, it is desirable that fluid is contained within capsule  10  and permitted to mix with ingredients and steep for a pre-determined time. The rate of dissolution of closure  42  may be determined/programmed at least in part by parameters of closure  42  such as thickness, density and composition (molecular weight and chemistry) as well as external factors such as fluid temperature and internal pressure. 
     Preferred materials for soluble closure  42  include protein or carbohydrate based materials which could be starch based (e.g., amylose film and amylopectin film), protein based (e.g., gelatin film, casein film), polysaccharide based (e.g., pullulan film, cellulose film), alginate sodium film and pectin film, to name a few. For example, the Vivos™ edible water soluble film from MonoSol™ can be employed as a membrane form of closure  42  in this application. As mentioned earlier, the dissolution rate of a soluble closure is dependent on the material type. Within the same type, the dissolution rate is normally slower when having heavier material density or molecular weight. Preferably the closure  42  thickness is in the range of 10-100 μm, more preferably 20-80 μm and most preferably 30-70 μm. 
     Soluble closure  42  may also be formed from ingredients  16 . An agglomeration of soluble and/or insoluble consumable ingredients  16   a  on their own or with a food safe binder material, similar to a bouillon cube, may for instance be formed into a plug that is disposed within aperture  40 . 
     An aperture cover  44 , preferably formed of a multilayered material that includes a barrier layer (preferably adapted to act as a barrier for one or more of moisture, oxygen, and light), is disposed over aperture  40  on an exterior surface of capsule  10  to provide a barrier seal for ingredients  16  within capsule  10 . Aperture cover  44  may include a tab  46  that may be gripped by a user to peel away aperture cover  44  and expose aperture  40 . It will be understood that closure  42  continues to cover aperture  40  following removal of cover  44  until use of capsule  10  in machine  20 . 
     During use, a user will remove cover  44  from capsule  10  and insert capsule into a corresponding capsule chamber within machine  20 . Machine  20  is activated by the user in order that injection system  22  injects fluid, such as heated water, into capsule  10 . Fluid mixes with ingredients  16  and dissolves closure  42 . Upon dissolution of closure  42 , aperture  40  is exposed and product (fluid plus extract from non-consumable ingredients  16   a,  if applicable, plus insoluble consumable ingredients  16   b ) is allowed to pass through aperture  40  into desired receptacle  26 . 
     Alternative embodiments of capsule  10  are described with reference to  FIGS. 2-14  below. Similar reference numerals are used to refer to similar elements as the embodiment discussed above. 
     Referring to  FIG. 2 , another embodiment of capsule  10  is shown. In this embodiment, capsule  10  does not include filter  14  or non-consumable ingredients  16   b.    
     Referring to  FIGS. 3( a ) and 3( b ) , another embodiment of capsule  10  is shown. In this embodiment, capsule  10  does not include filter  14  or non-consumable ingredients  16   b.  Capsule  10  further includes an exit nozzle  50  that is disposed in aperture  40  and adapted to be moved from a retracted position, prior to removal of cover  44 , to an extended position, following removal of cover  44 . In its extended position, exit nozzle  50  provides a clean disposable surface for product to flow through exit port  24   c  of machine  20  to receptacle  26 . 
     Exit nozzle  50  defines an aperture  52  that is closed by closure  42 . In this embodiment, closure  42  is in the form of a plug that is disposed in exit nozzle  50 . Exit nozzle  50  further includes a shoulder  54  that is adapted to prevent exit nozzle  50  from falling through aperture  40 . 
     In a variation of this embodiment, capsule  10  may be provided with exit nozzle  50  that is fixed in an extended position. Exit nozzle  50  and cover  44  may have corresponding threads (not shown) to allow cover  44  to be removably and threadably attached to exit nozzle  50 . Exit nozzle  50  may alternatively have a closed end and be adapted to be broken, cut open or pierced to expose aperture  52 . 
     Referring to  FIG. 4( a ) , another embodiment of capsule  10  is shown. In this embodiment, capsule  10  has a conventional shape similar to capsules  10  used for preparing beverage products. A conical insert  60  (as shown in isolation in  FIG. 4( b ) ) is disposed within capsule  10  to define second portion  30   b  of side wall  30  for directing product to aperture  40 . Conical insert may be secured in place with a sealing material or other suitable attachment means. Conical insert  60  is sized to avoid contact with dispensing system  24 . As a result, dispensing system  24 , such as probe  24   a  may puncture end wall  32  of capsule  10  without contacting second portion  30   b  of sidewall  30 . The advantage of the embodiment depicted in  FIG. 4( a )  is that the capsule resembles a conventional capsule and also has a flat base defined by end wall  32  to allow capsule  10  to rest on a flat surface prior to use. 
     Referring to  FIG. 5 , another embodiment of capsule  10  is shown. In this embodiment, at least some consumable ingredients  16   a  are contained within a soluble delivery system  70  in the form of a pouch  72 . Ingredients  16  may include liquid ingredients (such as a concentrate) or other ingredients that must be kept separated within capsule (such as foaming agents or other active ingredients). Soluble and insoluble consumable ingredients  16   a  may all be contained within a single delivery system  70  or may be separated into a plurality of delivery systems  70 . Non-consumable ingredients  16   b  may be contained separately within capsule  10  in a chamber defined by filter  14 . Soluble closure  42  is not required for this embodiment if all loose ingredients are contained within delivery system  70 . Soluble closure  42  may still be provided however in instances where certain consumable ingredients  16   a  are not contained within soluble delivery system  70 . Soluble closure  42  may also be provided as an added control over the dwell time of fluid within capsule prior to dispensing as discussed above. 
     Soluble delivery system  70  may be made of similar food safe materials as described above for soluble closure  42 . Delivery system  70  is adapted to dissolve when fluid is injected into capsule  10 . The rate at which delivery system  70  dissolves may be determined at least in part by parameters of delivery system  70  such as thickness, density and composition as well as external factors such as fluid temperature and internal pressure. 
     Referring to  FIGS. 6 and 7 , capsule  10  may include an alternate delivery system  70  in the form of a soluble film  80  comprising one or more layers  82  of ingredients  16  tied together with a soluble binder  84 . A soluble protective layer  86  may be provided to protect certain ingredients  16  contained within capsule  10  from exposure to other ingredients  16  contained within film  80 . Protective layer  86  may also protect ingredients  16  contained within film  80  from external elements during processing and handling. Protective layer  86  may have desired barrier properties to maintain the stability of ingredients  16  contained within film  80  until protective layer  86  is dissolved. 
     Film  80  may be disposed in capsule  10  for the purpose of adding microdoses of desired additives such as flavor, health or medicinal ingredients or active agents. In the case of certain sensitive additives, such as medicinal additives, film  80  may be formed at a third party manufacturing facility that meets the regulatory requirements for producing such ingredients and then delivered to a facility for manufacturing capsules  10 . 
     Referring to  FIGS. 8-9 ( c ), another embodiment of capsule  10  is shown. In this embodiment, capsule  10  has a similar construction to the capsule depicted in  FIGS. 4( a ) and 4( b ) . Capsule  10  may however be constructed in a similar manner to any of the other capsule embodiments above or such other constructions that are adapted for use in a machine  20  that allows prepared product to be dispensed through end wall  32  of capsule  10  into receptacle  26 . 
     In this instance, aperture cover  44  is adapted to remain in place over aperture  40  until capsule  10  is loaded into machine and fluid is injected into capsule  10 . As a result, soluble closure  42  is not required to block ingredients  16  from being dispensed from capsule  10  prior to use in machine  20 . However, one may still choose to include soluble closure  42  for other purposes, such as to prolong the period that fluid is contained within capsule  10  before being dispensed to a user&#39;s receptacle  26 . 
     Aperture cover  44  is preferably secured to the outer surface of end wall  32  using a food safe adhesive  100  (which may be similar to the materials used to form soluble closure  42  as described above). Adhesive  100  may comprise chemical based food grade adhesives, such as epoxy or silicone, or natural based food grade adhesives, such as protein or carbohydrate based materials. At least a portion of adhesive  100  is adapted to dissolve or separate from its bond to aperture cover  44  or end wall  32  when exposed to the internal pressure, heat and or moisture associated with the injection of fluid into capsule  10 . When the adhesive dissolves or separates, aperture cover  44  will open sufficiently to permit the contents of capsule  10  to be dispensed. 
     Preferably, aperture cover  44  is adhered to end wall  32  in a manner such that a portion of cover  44  remains adhered to end wall  32  while the remainder of cover  44  opens to permit the contents of capsule  10  to be dispensed. This may be achieved for example by utilizing a relatively stronger first adhesive  100   a  for adhering the portion of cover  44  that one wishes to remain adhered to end wall  32  and a relatively weaker second adhesive  100   b  that is adapted to dissolve or separate as discussed above. Alternatively, the same adhesive  100  may be used to adhere all portions of cover  44  to end wall  32  however the portion of cover  44  that one wishes to remain adhered to end wall  32  may have a greater surface area A of contact that is sufficient to maintain the adhesion of that portion of aperture cover  44  to end wall  32  when exposed to the internal pressure, heat and or moisture associated with the injection of fluid into capsule  10 . Examples of how this may be achieved are shown in  FIGS. 9( a ) and 9( b ) . 
     Alternatively, referring to  FIG. 9( c ) , cover  44  may be adhered in a manner that remains attached to end wall  32  following the injection of fluid into capsule  10  but has one or more separable portions  102  that are adapted to separate when exposed to the internal pressure, heat and or moisture associated with the injection of fluid into capsule  10 . Portions  102  may for example be connected together with a food safe adhesive  100  as discussed above or may include score lines  104  that are adapted to separate when exposed to the internal pressure, heat and or moisture associated with the injection of fluid into capsule  10 . 
     Referring to  FIGS. 10-14 , another embodiment of capsule  10  is shown. In this embodiment, capsule  10  includes at least one protrusion  110  defined in side wall  30  that is adapted to engage a portion of machine  20  in order to convert dispensing system  24  from one that pierces end wall  32  to one that pierces cover  18 . In other words, protrusion  110  acts as a cam for a corresponding follower (not shown) on machine  20  that causes dispensing system  24  to convert from one configuration to another. An example of such a machine is the Keurig 2.0™ system. 
     Capsule  10  further includes a void  120  that is adapted to receive probe  24   a  when dispensing system  24  is configured to pierce cover  18 . Void  120  is disposed on the exterior side of capsule  10  in order to avoid fluid from exiting capsule  10  through cover  18 . This allows capsule  10  to be used in a machine  20  having a dispensing system  24  that is adapted to pierce cover  18 . In this instance, probe  24   a  enters void  120  and thus avoids causing fluid from exiting capsule through cover  18 . Instead, as described further below, capsule  10  is provided with aperture  40  in end wall  32  to allow prepared product to be dispensed. 
     In one embodiment, as shown in  FIG. 11( a ) , void  120  is defined on the exterior side of side wall  30  between a pair of protrusions  120 . Flange  38  follows the contours of side wall  30  including protrusions  110  in order that void  120  extends to the top surface of capsule  10 . In an alternative embodiment, as shown in  FIG. 11( b ) , void  120  is defined in flange  38  at a location that is exterior to side wall  30 . One or more protrusions  110  extend from side wall  30  beneath flange  28 . 
     As shown in  FIGS. 12 and 13 , capsule  10  further includes filter  14  that contains ingredients  16 . Ingredients may for example include roast ground coffee or tea leaves. Alternatively, capsule  10  may be provided with no filter  14  in instances where it is desired that all ingredients  16  be dispensed into receptacle  26 . 
     Capsule  10  further includes aperture  40  and aperture cover  44  such as described above with reference to  FIGS. 8-9 ( c ). Aperture  40  is preferably offset or at least adapted to open on the side of end wall  32  that is aligned with protrusions  110  and void  120 . Machine  20  is adapted to hold capsule  10  at an angle when dispensing system  24  is converted to a position for piercing cover  18  with dispensing system  24  being located at the lowest point of the angled capsule  10 . As a result, it is desirable that aperture  40  is adapted to open at the lower point of the angled capsule  10  on the same side as void  120  to facilitate a gravity feed of prepared product being dispensed from capsule  10 . 
     Capsule  10  further includes a collar  130  extending along at least a portion of end wall  32  proximate to aperture  40 . Collar  130  is adapted to channel prepared product that is exiting aperture  40  toward a user&#39;s receptacle  26 . 
     While the above description provides examples of one or more processes or apparatuses, it will be appreciated that other processes or apparatuses may be within the scope of the accompanying claims.