Patent Publication Number: US-11040790-B2

Title: Capsule containing a dosing agent and system and process for making same

Description:
This application is a division U.S. application Ser. No. 15,224,706 filed on Aug. 1, 2016, which is a division of U.S. application Ser. No. 14,463,949 filed on Aug. 20, 2014, now U.S. Pat. No. 9,428,329, issued on Aug. 30, 2016, which claims the benefit for priority purposes of U.S. Provisional Application No. 61/867,819, filed on Aug. 20, 2013. 
    
    
     FIELD 
     This specification relates to capsules containing dosing agents for preparing a desired consumable product and systems and processes for making same. 
     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. 
     Capsules for use in machines to prepare a desired consumable product are becoming increasingly popular. Such capsules come in a variety of formats containing ingredients for producing consumable products such as coffee, tea, hot chocolate or soup. 
     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 to prepare a desired consumable product. A dispensing system may also be provided to dispense the prepared product from the capsule for delivery to a receptacle such as a user&#39;s cup or bowl. 
     A problem with conventional capsules is that it can be difficult to control the manner in which ingredients are exposed to fluid that is injected into the capsule. It may be desirable for example for certain ingredients to be mixed with fluid within the capsule for a longer period of time than other ingredients. It may also be desirable for certain ingredients to be separated from other ingredients within the capsule prior to, or for a desired period following, injection of fluid into the capsule. 
     Another problem with conventional capsules is that the fluid injected into the capsule may form one or more channels through the ingredients contained within the capsule along one or more axes of injection. This can result in fluid being dispensed from the capsule prior to adequately mixing with ingredients. Furthermore, some ingredients may not be sufficiently saturated with fluid to optimize the preparation of the desired product. 
     It is known to provide permanent structural elements within a capsule to manage the flow of fluid that is injected into the capsule. A problem with permanent structural elements is that they add to the cost and complexity of manufacturing the capsule. Permanent structural elements may also occupy space within the capsule which may be better utilized for other purposes. 
     It is desirable on occasion that a dosing agent, such as a flavoring component, is added to the capsule to produce a desired consumable product. Dosing agents are typically mixed with ingredients in large totes prior to loading the mixture into capsules. 
     A problem with this system is that a large number of totes are required in order to have an inventory of different mixtures to produce a desired batch of capsules. Alternatively, if only one or a few totes were available, the tote or totes need to be thoroughly cleaned after each use to prevent mixing of dosing agents. 
     There is a need for an improved capsule and an improved system and process for making capsules with a desired dosing agent. 
     SUMMARY OF THE DISCLOSURE 
     In one aspect, there is provided a process for making a capsule for use in a machine for preparing consumable products from capsules, the process comprising the steps of: 
     providing a body having an interior space and an opening; 
     depositing ingredients that are in a dry state into the interior space, the ingredients being adapted to form a consumable product when combined with fluid; 
     dispensing a dosing agent that is in a liquid state into the interior space; and 
     sealing the opening with a cover. 
     In another aspect, there is provided a system for making a capsule for use in a machine for preparing consumable products from capsules, the system comprising: 
     an ingredient station for depositing ingredients that are in a dry state into a body for the capsule, said body having an interior space and an opening, the ingredients being adapted to form a consumable product when combined with fluid; 
     a dosing agent station for dispensing a dosing agent that is in a liquid state into the interior space of the capsule; and 
     a cover sealing station for sealing a cover over the opening. 
     In another aspect, there is provided a capsule made according to the above described process. 
     In another aspect, there is provided a capsule, for use in a machine for preparing consumable products from capsules, said capsule comprising: 
     a. a body defining an interior space with an opening; 
     b. a filter disposed in said interior space to define an ingredients chamber, said filter being adapted for filtering ingredients during preparation of said consumable product; 
     c. a dosing agent disposed on a portion of said filter for controlling the flow of fluid through said filter; 
     d. ingredients disposed in said ingredients chamber for preparing a desired consumable product; and 
     e. a cover disposed over said opening. 
     In another aspect there is provided a capsule, for use in a machine for preparing consumable products from capsules, said capsule comprising: 
     a. a body defining an interior space with an opening; 
     b. ingredients disposed in said interior space for preparing a desired consumable product; 
     c. a dosing agent disposed in said interior space with said ingredients, wherein a portion of said ingredients and said dosing agent are non-permanently bound to form a cluster for controlling the flow of fluid through said filter; and 
     d. a cover disposed over said opening. 
     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 specific examples and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE 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 vertical cross-section of a capsule containing a dosing agent; 
         FIG. 2  is schematic view of a machine for preparing consumable products from capsules; 
         FIG. 3  is a schematic view of a dispenser for dispensing a dosing agent into a capsule; 
         FIG. 4  is a schematic view of a system for making capsules containing a dosing agent; 
         FIG. 5  is a diagram of a process for making capsules containing a dosing agent; 
         FIG. 6  is a top view of a capsule without ingredients showing a dosing agent applied to a portion of the filter; and 
         FIG. 7  is a sectional view of a capsule having a cluster formed as a layer within the ingredients. 
     
    
    
     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 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 . Capsule may be sized to provide a single serving of a desired product or multiple servings. 
     Ingredients  16  include soluble and/or insoluble ingredients that are a precursor to forming a desired product when combined with fluid as described further below. Preferably, ingredients  16  are provided in a dry state. Soluble ingredients may include instant coffee, chocolate, soup stock or other ingredients in powdered, crystallized or other forms adapted for solubility or contained within a soluble film or pouch. Insoluble ingredients may include tea leaves, coffee grounds, herbs or other ingredients adapted for forming a consumable product by extraction or infusion. Ingredients  16  may also include active ingredients (e.g., foaming agents), natural health additives, regulated drugs, alcohol or other soluble or insoluble ingredients. 
     Ingredients  16  may be disposed in a plurality of distinct regions R 1 , R 2  . . . Rn within capsule  10 . The same type of ingredients  16  may be disposed in each region R or different types of ingredients  16  may be disposed in different regions R. The density, cohesion or other physical properties of ingredients  16  may also vary between regions R. 
     Capsule  10  is sized and configured for use in a machine  20  that is adapted for preparing a product from capsule  10 . 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 hollow probe  24   a  that is adapted to pierce capsule  10  to dispense a prepared product from capsule  10 . 
     Body  12  of capsule  10  includes a sidewall  30  and an end wall  32  together defining an interior space  34 . An opening  36  is defined at one end of body  12  and a flange  38  extends around the perimeter of opening  36  to receive cover  18  and to support capsule  10  within machine  20 . 
     In another embodiment, body  12  may be formed with no end wall  32  and no sidewall  30  or a partial sidewall  30 . Flange  38  may still extend around the perimeter of opening  36  to receive cover  18  and to support capsule  10  within machine  20 . Filter  14  may be secured to flange  38  or to partial sidewall  30 . 
     Filter  14  is adapted to be disposed within body  12  to define at least one ingredients chamber for receiving one or more ingredients  16  and in particular insoluble ingredients  16  that are not intended to be dispensed into receptacle  26  (for example coffee grounds or tea leaves). 
     Filter  14  is preferably adapted to be phobic to the fluid being injected into capsule  10 . In most instances, the fluid will comprise water (either heated or cooled) and a hydrophobic filter  14  is desired. Filter  14  may be formed of materials that are phobic to fluid such as polyolefins (e.g., polyethylene, polypropylene) and mixtures of polyolefins with other polymers or filter  14  may be coated with materials that are phobic to fluid such as a polyethylene coating. 
     Preferably, filter  14  is formed of a moldable non-woven filtration material that includes a plurality of multi-component fibers that are bound or interlocked by non-woven manufacturing techniques (such as spun bond techniques) to form a web having channels extending from one side of filter  14  to the other. The desired diameter for channels after forming is between 20 and 100 μm, more preferably between 40 to 80 μm. More details of a preferred filtration material for filter  14  are provided in US patent publication 20140127364 which is hereby incorporated in its entirety herein by reference. 
     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 insoluble ingredients  16  are dispensed together with fluid into receptacle  26  (this requires that dispensing system be adapted to dispense insoluble ingredients  16 ). 
     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 as described in US patent publication 20130209618 which is incorporated herein in its entirety by reference. 
     A dosing agent  40 , preferably in a liquid state, is disposed within capsule  10  by means of a dispenser  50  (see  FIG. 3 ) prior to completion and sealing of capsule  10  as described further below. Dosing agent  40  may be a neutral dosing agent  40   a  or it may be an active dosing agent  40   b . A neutral dosing agent  40   a  does not add any noticeable flavor, odour, sensory, health benefit or function to the consumable product produced from capsule  10  but may combine with a portion of ingredients  16  to form a cluster  52  inside capsule  10  as described further below. Examples of neutral dosing agent  40   a  include polyethylene glycol, polypropylene glycol, ethyl alcohol etc. Conversely, an active dosing agent  40   b  provides a flavor, odour, sensory, health benefit or function to the consumable product and may also combine with a portion of ingredients  16  to form cluster  52 . Examples of active dosing agents  40   b  include flavor components such as Ethyl-2-methybutyrate (apple), 1-octen-3-ol, (mushroom), p-menthene-8-thiol (Grapefruit) or 5-methyl-2-hepten-4-one (Hazelnut). Active dosing agent  40   b  is employed either directly at a high concentration or diluted with a neutral dosing agent  40   a . Both neutral and active dosing agents are preferably highly water soluble. 
     In one embodiment, dosing agent  40  is applied to ingredients  16  disposed in capsule  10  in a manner that creates a cluster  52  formed of an agglomeration of a portion of ingredients  16  and dosing agent  40 . Cluster  52  may be formed as a clump or as a layer or crust formed of dosing agent  40  and ingredients  16 . Cluster  52  comprises a non-permanent structure that is adapted to at least partially dissolve or break apart within capsule  10  when exposed to a flow of fluid over a period of time (such as the period of time required to inject the desired amount of fluid into capsule  10 ). In one embodiment of the capsule  10 , the main beverage ingredient is ground coffee and dosing agent  40  is in the form of an oil or an oil-like product. 
     Cluster  50  may comprise a first region R 1  of ingredients  16  and dosing agent  40  disposed within capsule  10 . The remainder of ingredients  16  for capsule  10  may comprise a second region R 2  of capsule  10 . Second region R 2  may partially or fully surround first region R 1 . Ingredients  16  in second region R 2  may be loosely disposed within capsule  10  while ingredients  16  and dosing agent  40  in first region R 1  are formed into cluster  52 . 
     As shown in  FIG. 1 , cluster  52  is preferably disposed at a desired location  54  within capsule  10  that is adapted for controlling the flow of fluid injected into capsule  10 . Such fluid control may comprise dispersing a flow of fluid for a period of time, absorbing a flow of fluid for a period of time or otherwise controlling or altering the flow of fluid within capsule  10 . Location  54  may be selected according to the type of capsule machine  20  and injection system  22  for which capsule  10  is intended to be used as well as the type of ingredients  16  disposed within capsule  10 . Location  54  for K-Cup™ brewers for example may be along a central axis A of capsule  10  in line with the flow of fluid that is injected into capsule  10  through injection nozzle  22   a . Alternatively, location  54  may be along a transverse axis B where cluster  52  is formed as a layer or crust. In some instances it may be desirable for location  54  to be at a lower portion of capsule  10  and in other instances in may be preferable for location  54  to be at an upper location of capsule  10 . 
     Referring to  FIG. 3 , dispenser  50  comprises a device for dispensing dosing agent  40  in a desired manner and location within capsule  10 . In one embodiment, dispenser  50  comprises a nozzle  60 , a fluid body  62 , a fluid inlet  64 , a gas cylinder body  66  and a gas inlet  68  for dispensing a mix of dosing agent  40  and a gas into capsule  10 . Fluid body  62  is adapted to receive dosing agent  40  through fluid inlet  64  from a dosing agent supply tank (not shown). Gas cylinder body  66  is adapted to receive a desired gas through gas inlet  68  from a gas supply tank (not shown). Gas and dosing agent  40  are mixed within dispenser  50  and dispensed as a pressurized stream or spray through nozzle  60 . In other embodiments, dispenser  50  may dispense dosing agent  40  through nozzle  60  without mixing with a source of gas. In such embodiments, dispenser  50  comprises a fluid body  64  and fluid inlet  64  connected to nozzle  60 . 
     Dosing agent  40  may be applied to ingredients  16  by inserting nozzle  60  partway into ingredients  16  to form cluster  52 . Alternatively, dosing agent  40  may be dispensed under pressure over the surface of ingredients  16  without inserting nozzle  60  into ingredients  16 . This latter approach avoids direct contact between nozzle  60  and ingredients  16 . Dispensing dosing agent  40  under a desired pressure over the surface of ingredients  16  still allows cluster  52  to be formed at a desired location  54  based on factors such as the dispensing pressure of dosing agent  40  and the density of ingredients  16 . Alternatively, dosing agent  40  may be applied by dispenser  50  to filter  14  or sidewall  30  or endwall  32  of capsule  10  prior to adding ingredients  16 . Alternatively, capsule  10  may be partially filled with ingredients  16  and then dosing agent  40  may be applied to ingredients  16  and then the remaining ingredients  16  may be added to capsule. 
     Referring to  FIGS. 4 and 5 , schematic views of a system  100  and a process  1000  for making capsules  10  is shown. 
     System  100  comprises at least one transfer belt  102  having a plurality of capsule holders  103  adapted to cyclically and sequentially transfer capsules  10  from a working station to a following station as described further below. While only a single capsule holder  103  is shown at each station for system  100  it will be understood that transfer belt  102  has multiple capsule holders  103  disposed at each station in order that manufacturing operations may be performed simultaneously on multiple capsules at each station. 
     System  100  includes a body forming station  104  for engaging a sheet of moldable multilayered body material  106  with a heated mandrel  108  to form body  12  in accordance with body forming step  1002 . Capsule holder  103  with body  12  formed in body material  106  is then transferred to a filter sealing station  110  (if a filter  14  is desired, otherwise capsule holder  103  with body  12  is transferred directly to cutting station  120  as described below). A sheet of moldable nonwoven filter material  112  is sealed to body material  106  at filter sealing station  110  in accordance with filter sealing step  1004  such that filter material  112  covers opening  26  of body  12 . 
     Capsule holder  103  with filter material  112  sealed to body material  106  is then transferred to a filter forming station  116  where a heated mandrel  118  engages the portion of filter material  112  that extends over opening  26  of body  12  to form a filter  14  into a desired shape to define an ingredients chamber  46  within thermoformed body  12  in accordance with filter forming step  1006 . 
     Capsule holder  103  with filter material  112  sealed to body material  106  and filter  14  formed in body  12  is then transferred to a cutting station  120  where a die  122  cuts each individual body  12  with filter  14  from body material  106  in accordance with cutting step  1008 . Die  122  is adapted to cut body material  106  to define flange  28  around opening of body  12  with a gasket portion of filter  14  sealed to the top surface of flange  28 . 
     Capsule holder  103  with separated body  12  with filter  14  is then transferred to an ingredients station  124  having an ingredients supplier  126  for supplying a desired amount of ingredients  16  into ingredients chamber  46  in accordance with ingredients loading step  1010 . A scale  128  weighs beverage capsule  10  to ensure that the desired amount of ingredients  16  have been disposed into ingredients chamber  46 . 
     Capsule holder  103  then transfers body  12  with filter  14  and ingredients  16  to dosing agent station  130  having a dispenser  50  for dispensing a desired amount of dosing agent  40  into ingredients  16  in accordance with dosing step  1012 . 
     A desired amount of liquid dosing agent  40  for a single serve capsule having 8-10 grams of dry ingredients  16  is in the range of 0.2-2.0 cc. Dosing agent  40 , alone or in combination with a gas, can be expelled through nozzle  60  of dispenser  50  into capsule  10 . Typically the gas is an inert gas such as nitrogen, not air, in view of the need to keep oxygen away from certain types of ingredients  16  such as roasted ground coffee. In one embodiment, for producing capsules  10  containing loosely filled dry ground coffee or tea, dosing agent  40  is delivered under pressure at a preferred range of 10-50 psi and the dosing time is approximately 0.1 to 0.2 seconds. The amount of dosing agent  40  that is dispensed can be adjusted through varying the orifice size of the nozzle  60 , through controlling the time of injection and/or through controlling pressure. 
     Following dosing step  1012 , capsule holder  103  then transfers body  12  with filter  14  and ingredients  16  with dosing agent  40  to cleaning station  132  where a vacuum conduit  134  cleans the exposed surface of flange  28  or gasket portion  50  of filter  14  in preparation for sealing with cover  18  in accordance with cleaning step  1014 . 
     Capsule holder  103  then transfers body  12  with filter  14  and ingredients  16  with dosing agent  40  to a cover pre-sealing station  136  for receiving a supply of a cover material  138  and pre-sealing a portion of cover  18  to gasket portion  50  of filter  14  and to flange  28  of body  12  in accordance with pre-sealing step  1016 . Cover pre-sealing station  136  leaves openings  188  along edge of cover  18  for allowing air to be evacuated and inert gas to be flushed into capsule during the modified atmosphere packaging (MAP) process step  1018  as described in more detail below. 
     Partially sealed capsules  10  are then transferred from capsule holders  103  in transfer plate  102  to corresponding capsule holders  176  disposed within a transfer plate  178  using a pick-and-place device (not shown) or other suitable mechanism. Capsule holders  176  and transfer plate  178  are specially adapted for use during the MAP process step  1018 . 
     Transfer plate  178  with partially sealed beverage capsules  10  disposed in capsule holders  176  is then moved to a MAP station  170  for execution of the MAP process step  1018  as described in more detail in US patent publication 20140141128 which is incorporated herein in its entirety by reference. Once the MAP process is complete, openings  188  in cover  18  are sealed with sealer  192  in accordance with sealing step  1020  and the finished capsule  10  is transferred using a pick-and-place device (not shown) or other suitable mechanism to a collection station  140  for subsequent packaging into boxes (not shown). 
     It will be understood that system  100  and process  1000  do not require all stations and steps to be provided. It will also be understood that the relative position of stations or the order of process steps may be changed depending on the desired structure and contents of the finished capsule  10 . 
     For example, dosing agent  40  may be sprayed by means of dispenser  50  onto filter  14  as shown in  FIG. 6  before ingredients  16  are loaded into capsule. Dosing agent  40  may be selected to provide a layer over a portion of filter to control the flow of fluid through filter. Dosing agent  40  may be formed of a soluble or insoluble material depending on how one wishes to control the flow of fluid through filter. 
     In another example, dosing agent  40  may be applied to the surface of ingredients  16  that are loaded into capsule  10  to form cluster  52  as a layer or crust of agglomerated ingredients  16 . As shown in  FIG. 7 , a portion of ingredients  16  may be loaded into capsule  10 , followed by an application of dosing agent  40  to form cluster  52  and then followed by the remainder of ingredients  16 . It will be understood that the stations and process steps may be changed to allow for partial loading of ingredients  16 , followed by dispensing of dosing agent, followed by loading of the remaining ingredients  16 . 
     While the above description provides examples of one or more beverage capsules and processes for manufacturing same, it will be appreciated that other beverage capsules and processes may be within the scope of the accompanying claims.