Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: CAPSULE FOR PREPARING CONSUMABLE PRODUCT
FIELD
[0001] This specification relates to consumable products and in particular
to capsules for preparing a consumable product.
BACKGROUND
[0002] The following background discussion is not an admission that
anything discussed below is citable as prior art or common general knowledge.
[0003]
[0003] 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.
[0004] 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'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 the
probe
from the capsule for delivery to a desired receptacle.
[0005] 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
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example, vegetables and noodles for a soup product will not flow through a
conventional hollow probe dispensing system for a capsule machine.
[0005]
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.
[0006]
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).
[0007] 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
[0008] In one
aspect the invention provides a capsule, for use in a
machine for preparing consumable products from capsules, said capsule
comprising:
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a body defining an interior space with an opening at one location and an
aperture
at another location;
a soluble closure disposed in said body for closing said aperture;
ingredients disposed in said interior space for preparing a desired product;
a cover disposed over said opening; and
a removable cover disposed on an exterior surface of said body over said
aperture..
[0009] In
another 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;
a soluble delivery system disposed in said body, said soluble delivery system
containing ingredients for preparing a desired product;
a cover disposed over said opening; and
a removable cover disposed on an exterior surface of said body over said
aperture.
[0010] 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
[0011] 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
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be repeated among the drawings to indicate corresponding or analogous
elements.
[0012] Figure
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;
[0013] Figure
2 is a vertical sectional view of another embodiment of
capsule in accordance with the present invention;
[0014] Figure
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;
[0015] Figure
3(b) is a vertical sectional view of the capsule as shown in
Figure 3(a), with the exit nozzle disposed in an extended position;
[0016] Figure
4(a) is a vertical sectional view of another embodiment of
capsule in accordance with the present invention;
[0017] Figure
4(b) is a perspective view of a conical insert for use with the
capsule shown in Figure 4(a);
[0018] Figure
5 is a vertical sectional view of another embodiment of
capsule in accordance with the present invention;
[0019] Figure
6 is a vertical sectional view of another embodiment of
capsule in accordance with the present invention; and
[0020] Figure
7 is a schematic enlarged sectional view of the dispensing
system for the capsule shown in Figure 6.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0021]
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
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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.
[0022] 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.
[0023]
Ingredients 16 may include soluble and insoluble ingredients.
Insoluble ingredients may include consumable ingredients 16a (ingredients,
such
as noodles and dried vegetables, that are intended to be consumed as part of
the
prepared product) and non-consumable ingredients 16b (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.
[0024]
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 22a 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
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cover 18, and adapted to pierce body 12 and interact with machine 20 to inject
fluid into capsule 10.
[0025]
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 24a that is adapted to pierce
capsule 10 to dispense a prepared product from capsule 10. Dispensing system
24 may further include a collection chamber 24b and exit port 24c, downstream
from hollow probe 24a for collecting and dispensing prepared product into
receptacle 26.
[0026]
Capsule 10 may be configured to avoid interaction with hollow
probe 24a for use in cases where a conventional hollow probe 24a is not
adapted
for dispensing insoluble consumable ingredients 16a. Such ingredients 16a may
become clogged within the small diameter channel defined in hollow probe 24a.
[0027] 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 30a
and a
second portion 30b. Second portion 30b 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 30a to end wall 32 sufficiently to
avoid
contact with dispensing system 24.
[0028] An
opening 36 is defined at one end of body 12 and a flange 38
extends around the perimeter of opening 36.
[0029] 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 16b. 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 Figure 2).
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[0030] 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.
[0031] An
aperture 40 is defined in end wall 32 for dispensing product from
capsule. Aperture 40 is sized to allow product including consumable
ingredients
16a to pass through aperture 40 without clogging. Preferably aperture 40 has a
diameter in the range of 5-50 mm, more preferably 10-30mm and most preferably
15-25 mm.
[0032] Second
portion 30b of side wall 30 tapers inwardly from first portion
30a to aperture 40. Second portion 30b thus directs product within capsule 10,
including consumable insoluble ingredients 16a, toward aperture 40.
[0033] A
soluble closure 42 is provided to close aperture 40 to prevent
consumable ingredients 16a 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.
[0034]
Soluble closure 42 may for example be in the form of a membrane
(as shown in Figures 1, 2 and 4) that covers aperture 40 or in the form of a
plug
(as shown in Figures 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.
[0035]
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
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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.
[0036]
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 Vivostm edible water soluble film
from MonoSol Tm 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 pm, more
preferably
20-80 pm and most preferably 30-70 pm.
[0037]
Soluble closure 42 may also be formed from ingredients 16. An
agglomeration of soluble and/or insoluble consumable ingredients 16a 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.
[0038] A
removable 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
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10. Removable cover 44 may include a tab 46 that may be gripped by a user to
peel away removable 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.
[0039] 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 16a, if applicable, plus
insoluble consumable ingredients 16b) is allowed to pass through aperture 40
into desired receptacle 26.
[0040]
Alternative embodiments of capsule 10 are described with
reference to Figures 2-7 below. Similar reference numerals are used to refer
to
similar elements as the embodiment discussed above.
[0041]
Referring to Figure 2, another embodiment of capsule 10 is shown.
In this embodiment, capsule 10 does not include filter 14 or non-consumable
ingredients 16b.
[0042]
Referring to Figures 3(a) and 3(b), another embodiment of capsule
is shown. In this embodiment, capsule 10 does not include filter 14 or non-
consumable ingredients 16b. 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 24c of machine 20 to receptacle 26.
[0043] 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
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nozzle 50. Exit nozzle 50 further includes a shoulder 54 that is adapted to
prevent exit nozzle 50 from falling through aperture 40.
[0044] 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.
[0045]
Referring to Figure 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 Figure 4(b)) is disposed within capsule 10 to define second
portion
30b 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 24a may puncture end wall 32 of capsule
10 without contacting second portion 30b of sidewall 30. The advantage of the
embodiment depicted in figure 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.
[0046]
Referring to Figure 5, another embodiment of capsule 10 is shown.
In this embodiment, at least some consumable ingredients 16a 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 16a may all be
contained within a single delivery system 70 or may be separated into a
plurality
of delivery systems 70. Non-consumable ingredients 16b may be contained
separately within capsule 10 in a chamber defined by filter 14. Soluble
closure 42
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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 16a 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.
[0047]
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.
[0048]
Referring to Figures 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.
[0049] 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.
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[0050] 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.
