Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation in part of U.S. patent application Ser. No. 14/609,215, filed Jan. 29, 2015, now U.S. Pat. No. 9,167,844 which claims the benefit of Provisional Patent Application Ser. No. 62/084,443, filed on Nov. 25, 2014, the entire contents of which are expressly incorporated herein by reference. 
    
    
     STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT 
     Not Applicable 
     BACKGROUND 
     The various aspects and embodiments described herein relate to instant hot water drinks. 
     Current concentrates are currently marketed in large containers that the end user must measure and dissolve in liquid or in prepackaged quantities that must be broken open and dropped into water. Unfortunately, there are certain deficiencies in the art regarding these concentrates. 
     Accordingly, there is a need in the art for an improved method and device for delivering edible concentrates. 
     BRIEF SUMMARY 
     A capsule containing a concentrate that can be dissolved in hot water within about 10 seconds to about 30 seconds and a machine for fabricating the capsule is shown. The capsule may have a rugged food grade exterior shell fabricated from a gelatin material. This exterior shell protects a concentrate contained in the exterior shell during handling, storage and other deleterious effects from outside forces. A food grade paraffin may be coated on an interior surface of the exterior shell to protect the exterior shell from interaction with the concentrate disposed within the center of the capsule. The concentrate may be a water-based liquid or solid disposed within the food grade exterior shell and separated from that food grade exterior shell by coating the interior surface thereof with the food grade paraffin. During storage and handling, the food grade exterior shell is sufficiently rugged to allow for dropage, pressure, etc. without breaking the exterior shell and spilling the water-based liquid or solid concentrate. In order to mix the concentrate with water, the capsule is submerged in hot water which eventually melts the paraffin coating to allow the water-based concentrate to interact with the exterior shell to dissolve the exterior shell and release the concentrate. 
     More particularly, a capsule dissolvable in hot water is disclosed. The capsule may comprise a food grade exterior shell, a food grade paraffin coating and a water based liquid or solid. The food grade exterior shell may be fabricated from a gelatin material. The food grade paraffin coating may be disposed on an interior surface of the food grade exterior shell. The food grade paraffin may have a melting temperature at least about 130° F. The water based liquid or solid may be disposed within the food grade exterior shell and separated from the food grade exterior shell by the food grade paraffin coating. To release the water based liquid or solid, the capsule may be disposed within hot water having a temperature of at least about 130° F. By doing so, the food grade exterior shell is dissolved and the paraffin coating melts so that the water based solid or liquid interacts with the exterior shell to dissolve the exterior shell to release the water based liquid or solid into the water. 
     The food grade paraffin may have a melting temperature at least between 130° F. to 200° F. 
     The water based liquid or solid may mix homogenously with the water. 
     A thickness of a wall of the food grade exterior shell may be between about 0.2 mm and about 3 mm. A thickness of the food grade paraffin coating may be between about 0.05 mm and about 2 mm. 
     The food grade paraffin coating may be oil based. 
     The food grade exterior shell may be sufficiently rugged for transportation of the capsule over trucks, trains and planes. 
     The water based liquid or solid may be coffee extract, tea extract, food flavoring or combinations thereof. 
     In another aspect, a method of producing a capsule which is dissolvable in hot water is disclosed. The method may comprise the steps of forming first and second ribbons of a gelatin material, each of the first and second ribbons defining an interior surface and an exterior surface; coating the interior surfaces of the first and second ribbons with a food grade paraffin; guiding the first and second ribbons between first and second rollers; disposing a water based liquid or solid between the first and second ribbons; and molding a plurality of capsules with the first and second rollers to encapsulate the water based liquid or solid within the capsules. 
     The coating step may comprise the step of spraying the food grade paraffin in liquid form on the interior surfaces of the first and second ribbons. The forming step may comprise the step of forming the first and second ribbons to be between about 0.2 mm and about 3 mm. The disposing step may includes the step of injecting a material having a viscosity between about 5,000 cP and about 10,000 cP. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which like numbers refer to like parts throughout, and in which: 
         FIG. 1  is a perspective view of a plurality of capsules disposed within the container; 
         FIG. 2  is a cross-sectional view of one of the capsules shown in  FIG. 1 ; 
         FIG. 3  is a flowchart for forming the capsule; 
         FIG. 4  is a front elevational view of a machine for forming the capsule; 
         FIG. 5  is an enlarged top perspective view of a portion of the machine shown in  FIG. 4 ; 
         FIG. 6  is an enlarged bottom perspective view of a portion of the machine shown in  FIG. 4 ; 
         FIG. 7  illustrates the process shown in  FIG. 4  with an additional sprayer for spraying on additives; 
         FIG. 8  is an alternate embodiment of the process shown in  FIG. 4 ; and 
         FIG. 9  illustrates the process shown in  FIG. 8  with the addition of sprayers for spraying on additives; 
         FIG. 10  is a perspective view of a second embodiment of the capsule; and 
         FIG. 11  is a cross-sectional view of the second embodiment of the capsule shown in  FIG. 10 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, a capsule  10  is shown. The capsule does not dissolve even when exposed to humid conditions. As such, the capsule  10  retains its shape and integrity during storage over a long period of time and transportation. The capsule  10  has an exterior shell  12  that is sufficiently rugged to handle normal handling during transportation and storage without cracking or breaking. It also does not degradate due to moisture in the air. An interior surface of the exterior shell  12  may be coated with a paraffin  14  and provides a layer of separation between the exterior shell  12  and a concentrate  16  disposed within the capsule  10  so that the concentrate  16  does not degrade the exterior shell  12 . In this regard, the exterior shell  12  may be fabricated from a water dissolvable material and the concentrate  16  may be a water-based material. Due to the paraffin coating  14 , the water in the concentrate  16  does not dissolve or degrade the exterior shell  12 . To release the concentrate  16 , the capsule  10  may be placed in hot water wherein the hot water is at a temperature sufficient to melt the paraffin  14 . By melting the paraffin  14 , the concentrate  16  then interacts with the exterior shell  12  which in our example would dissolve the exterior shell  12  so that the concentrate  16  excretes out of the exterior shell  12 . 
     Referring now to  FIG. 1 , a plurality of capsules  10  is shown as being contained within a container  18 . The capsule  10  has a rugged exterior shell  12  that is capable of withstanding normal forces due to transportation over truck, train and plane and also the weight of other capsules  10  so that the concentrate  16  does not leak out of the capsule  10  during storage and handling. The exterior shell  12  may be fabricated from a food grade gelatin material. By way of example and not limitation, the food grade gelatin material may be amylose, pullulan, guar gum, callaneenan, cellulose or combinations thereof. The exterior shell  12  may have a spherical configuration and be approximately 0.2 mm thick  20 . 
     The food grade gelatin material may be dissolvable in water. Preferably, the food grade gelatin material dissolves relatively slowly in cold water but quickly in hot water. By way of example and not limitation, the amount of food grade gelatin material and thickness of the exterior shell  12  may be adjusted such that the exterior shell  12  dissolves within about 10 to about 30 seconds when submerged in hot water at a temperature above 130° F. 
     Although the capsule  10  has been described as having a food grade exterior shell  12  fabricated from a gelatin material, other types of materials are also contemplated including but not limited to thermoplastic starch, polyvinyl alcohol, aliphatic copolyester, aliphatic/aromatic copolyester, polyactic acid, and blends of these polymers, and also polyethelene, polyethylene terephthalate and polyvinyl chloride. These other materials may be non-food grade materials. 
     An interior surface of the exterior shell  12  may be coated with paraffin  14 . The paraffin  14  acts as a barrier between the exterior shell  12  and the concentrate  16  located within the capsule  10 . The paraffin  14  is inert and does not react with the concentrate  16  or the exterior shell  12  so that the concentrate  16  can be preserved over a long period of time. The paraffin  14  may be a food grade paraffin  14  and may be coated on the interior surface of the exterior shell  12 . In order to release the concentrate  16 , the capsule  10  may be heated to a temperature above the melting temperature of the paraffin  14 . By way of example and not limitation, paraffin  14  may have a melting temperature of about 130° F. As such, in order to release the concentrate  16 , the capsule  10  may be placed within hot water or otherwise heated which would dissolve the exterior shell  12  from the outside. Also, the paraffin  14  would melt in order to allow the concentrate  16  to interact with the exterior shell  12  to dissolve the exterior shell  12  from the outside. The concentrate  16  is released and quickly dissolved in the hot water within about 10 seconds to about 30 seconds. 
     The paraffin  14  may be sprayed on the interior surface of the exterior shell  12  during manufacture of the capsule  10 . The paraffin  14  may have a thickness  22  of about 0.2 mm. Although the paraffin  14  is preferably sprayed on the interior surface of the exterior shell  12 , the paraffin  14  may also be melted and spread over the interior surface of the exterior shell  12 . The thickness  22  of the paraffin  14  may be adjusted (e.g., increased) in order to ensure that even minor degradation in the paraffin  14  will not cause the concentrate  16  to be placed in contact with the exterior shell  12 . 
     The paraffin  14  is described as having a melting temperature of about 130° F. However, other materials having higher or lower melting temperatures are also contemplated. These other materials may also be food grade so that they can be consumed by a person. 
     The concentrate  16  may be a water-based liquid or a solid. When the paraffin  14  is melted away, the water content within the water-based liquid or solid reacts with the exterior shell  12  to dissolve the same from the inside-out. In this manner, the interaction speeds up the disintegration of the capsule  10  when heated such as by placing the capsule  10  in hot water. The concentrate  16  may be dissolvable in water so that when the exterior shell  12  dissolves in water and the paraffin  14  melts away, the concentrate  16  may mix with the water. By way of example and not limitation, the concentrate  16  may dissolve in water in order to provide for a homogeneous solution or may be dispersed within the water in order to provide for a heterogeneous solution. Moreover, the concentrate  16  may be partially dissolvable in water to provide for a mixed homogeneous and heterogeneous solution/mixture. 
     Referring now to  FIG. 3 , a process for manufacturing the capsule  10  is shown. The process may begin with providing  100  a gelatin formulation. The gelatin is melted and formed  102  into two ribbons  24   a, b . As shown in  FIG. 4 , two ribbons  24   a, b  are shown which each form one half of the exterior shell  12  of the capsule  10 . Simultaneously, a paraffin formulation is provided  104  and is melted so that the melted paraffin  14  can be disposed  106  (e.g., sprayed or spread) on a surface of the ribbon  24   a, b  that defines the interior surface of the exterior shell  12 . Sprayers  26   a, b  may be placed above the ribbons  24   a, b  in order to spray the melted paraffin  14  on the ribbon  24   a, b . A water dissolvable material (e.g., concentrate  16 ) may be introduced  108  into a cavity formed by the ribbons  24   a, b  within injector  28 . First and second rotary clamshells  30   a, b  form  110  the capsule  10  into a spherical shape, as shown in  FIG. 4 . 
     Referring now to  FIG. 5 , a partially enlarged view of the machine shown in  FIG. 4  is shown. The ribbon  24   a  is guided on a series of rollers  32 ,  32   a  to a position between the clamshells  30   a, b . The sprayer  26   a  is located above the ribbon  24   a  and positioned so that the melted paraffin covers the entire width of the ribbon  24   a . The ribbon  24  may travel at a slow speed so that the melted paraffin  14  dries up or is semi-malleable before the concentrate  16  is injected with the injector  28  and the concentrate  16  is formed. The rollers  32   a, b  may have a plurality of semi-spherical cavities  34  to contour the ribbon  24   a, b  into the spherical shape configuration. The clamshells  30   a, b  may have a plurality of semi-spherical cavities  34  that mate with each other to form the spherical configuration of the capsule  10 . As the clamshells  30   a, b  rotate, corresponding semi-spherical cavities  34   a, b  mate up with each other and form the spherical configuration of the capsule  10 . The clamshells  30   a, b  may be heated so that the ribbons  24   a, b  may be formed and cut. The injector  28  pressurizes the interior of the cavity formed by the ribbons  24   a, b  in order to push the ribbons  24   a, b  into conformity with the configuration of the semi-spherical cavity  34 . 
     Thereafter, the capsule  10  is attached to the joined ribbon  24   a, b  and eventually falls to the sides and is then collected in the container  18 . 
     Although the capsule  10 , and more particularly, an outer surface of the exterior shell  12  was described as having a spherical configuration, other configurations are also contemplated such as cube, pyramidal, etc. The cavities  34   a, b  would form one half of the alternate configuration. 
     In another embodiment, the exterior shell  12  may be fabricated from a material that is non-dissolvable in water. However, the material of the exterior shell  12  may be reactive with a substance  16 . The interior surface of the exterior shell  12  may be coated with a coating  14  that is non-reactive with the substance  16  but may be melted at a temperature. The interior of the exterior shell  12  and the coating  14  may hold the substance  16  or a derivative thereof. When the product is immersed in water, the exterior shell  12  does not disintegrate to expose the substance  16  within the product. However, when the product is heated by disposing the product in hot water or applying heat to the product, the coating  14  melts away so that the substance  16  interacts with interior surface of the exterior shell  12 . Such interaction disintegrates or dissolves the exterior shell  12  so that the substance  16  leaks out of the exterior shell  12 . 
     Referring now to  FIG. 7 , the process for manufacturing the capsule  10  shown in  FIG. 3  may also have an additional sprayer  40   a ,  40   b . The sprayers  40   a, b  may spray an additive. By way of example and not limitation, such additives may be a preservative, vitamin fortification, flavor enhancement or combinations thereof. Once the additive is sprayed onto the surface of the ribbon  24   a, b , the paraffin  14  locks the additive between the paraffin  14  and the ribbon  24   a, b  so that the concentrate  16  does not interact with the additive. 
     Referring now to  FIG. 8 , in lieu of the sprayers  26   a, b  for spraying paraffin  14  on the ribbons  24   a, b , it is also contemplated that a paraffin ribbon  42   a, b  may be formed and fed between the rotary clamshells  30   a, b  which attaches (e.g., fuses) the ribbon  24   a  to ribbon  42   a  and ribbon  24   b  to ribbon  42   b . Referring now to  FIG. 9 , sprayers  40   a, b  may spray additives on the ribbons  24   a, b . The additive  44  may be locked between ribbons  24   a, b  and  42   a, b.    
     The concentrate  16  discussed herein may be a coffee extract, tea extract, food flavoring or combinations thereof. The concentrate  16  may be a coffee extract so that upon dissolution into hot water, one capsule dissolved in 8 fluid ounces of hot water will form regular strength hot coffee. Different concentrations of the concentrate  16  are also contemplated in that the concentrate  16  may have a potency so that one or more capsules mixed in a certain number of fluid ounces would form regular strength hot coffee. By way of example, three (3) capsules dissolved in 8 fluid ounces of hot water may form regular strength hot coffee. By inserting more or less concentrate in hot water, the strength of the hot coffee may be regulated. More concentrate will produce stronger coffee. Less concentrate will produce weaker coffee. Although the various aspects and embodiments were discussed in relation to the concentrate, it is also contemplated that the concentrate  16  may be non-concentrated or normal concentration for the purposes of mixing a substance in hot water. 
     The capsules  10  may also be dipped in a flavored liquid that solidifies when removed from the flavored liquid. The flavored liquid may be a chocolate coating or other liquefied food product. The flavored liquid may also solidify and adhere to the exterior of the capsule  10  when the flavored liquid is dried out when the capsule  10  is removed from the flavored liquid or when the dipped capsule  10  with the flavored liquid coated on the outside of the capsule  10  is heated. 
     Referring now the  FIGS. 10 and 11 , a second embodiment of the capsule  10   a  is shown. The capsule  10   a  is shown as having two compartments  50   a, b . However, it is also contemplated that the capsule  10   a  may have additional compartments  50   c - n . These additional compartments  50  may be stacked upon or laid adjacent to each other as shown in  FIG. 11 . 
     The capsule  10   a  may have three dissolvable layers  52   a, b  and  54  to form two compartments  50   a, b . The layers  52   a, b ,  54  may be fabricated from a cellulose-based material that can fully dissolve in water in under 1 minute. By way of example and not limitation, the layers  52   a, b    54  may be fabricated from amylose, pullulan, guar gum, callaneenan, cellulose or combinations thereof. For example, the cellulose based layer  52   a, b ,  54  may comprise a combination of decaglycerin monitor myristate (CAS No. 74504-63-5 and 87390-32-7), glycerin (CAS No. 56-81-5), crystalline cellulose (9004-34-6), and hydroxypropylcellulose (CAS No. 9004-64-2). The layers  52   a, b  form the exterior shell  12   a  of the capsule  10   a . In this regard, the layers  52   a, b  are preferably fabricated to be rugged in order to withstand normal handling during transportation, usage and storage. By way of example and not limitation, layers  52   a, b  may be fabricated to have a thickness  56  which is greater than the thickness  58  of the inner layer  54 . The thickness  56  of the exterior layers  52   a, b  may be sufficient to prevent the layers  52   a, b  from ripping, separating or otherwise allowing the contents within the compartments  50   a, b  from leaking out of the capsule  10   a  during handling, transportation and storage. 
     The compartments  50   a, b  may contain different food products. By way of example and not limitation, the food product disposed within compartments  50   a, b  may be a powdery substance consumable by a person or animal. The food product may be mixed in water when the capsule  10   a  is disposed in water. The water may be at a temperature of approximately 68° F., or more broadly, between 60° F. and 90° F. When the capsule  10   a  is disposed in water, the water dissolves the layers  52   a, b  in order to allow the food products disposed in the compartments  50   a, b  to be mixed with the water. 
     The food product disposed within the compartment  50   a  may be a coffee concentrate, strawberry concentrate, etc. The food product disposed within the adjacent compartment  50   b  may be complementary to the food product disposed within the compartment  50   a . By way of example and not limitation, the food product disposed within the adjacent compartment  50   b  may be a powdered creamer to be paired with the coffee concentrate or granulated sugar to be paired with the strawberry concentrate. The food products within the compartments  50   a, b  may complement one another so that when the capsule  10   a  is disposed in water, the food products in the compartments  50   a, b  are eventually mixed with each other to enhance the taste of the drink. 
     Preferably, the food products disposed in compartments  50   a, b  are not a water-based liquid. Rather, the food product disposed in the compartments  50   a, b  are a solid object such as a powdery substance. However, it is also contemplated that the inner surfaces of the layers  52   a, b  as well as the opposed surfaces of the layer  54  may be coated with a paraffin wax. In doing so, water-based liquids may then be disposed within the compartments  50   a, b  since the paraffin wax layer separates the liquid from the layers  52   a, b  and  54 . The paraffin wax layer also helps to strengthen the layers  52   a, b  so that the layers  52   a, b  do not rip or tear during normal transportation, storage or use. 
     Additionally, the entire capsule  10   a  can be dipped within a liquid which coats the exterior of the shell  12   a  and is subsequently hardened in order to form an additional liquid layer that encapsulates the entire capsule  10   a . This additional outer coating also helps to strengthen the layers  52   a, b  so that the layers  52   a, b  do not tear or rip during normal transportation, storage or use. 
     In order to fabricate capsule  10   a , food products are disposed between the layers  52   a, b  and layer  54 . Once the food product is disposed between the layers  52   a, b ,  54 , the outer peripheral portion  60  is crimped together with pressure and heat by way of heat sealing so that the outer peripheral portion  60  forms an airtight seal and the food products cannot leak out of the capsule  10   a.    
     The above description is given by way of example, and not limitation. Given the above disclosure, one skilled in the art could devise variations that are within the scope and spirit of the invention disclosed herein, including various ways of forming the capsules. Further, the various features of the embodiments disclosed herein can be used alone, or in varying combinations with each other and are not intended to be limited to the specific combination described herein. Thus, the scope of the claims is not to be limited by the illustrated embodiments.

Technology Category: 1