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. The documents listed below are incorporated herein in their entirety by this reference to them.

[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 or around 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 example, vegetables and noodles for a soup product will not flow through a conventional hollow probe dispensing system for a capsule machine. [0006] 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.

[0007] 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).

[0008] 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

[0009] 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.

[0010] 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.

[0011] 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

[0012] 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.

[0013] 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;

[0014] Figure 2 is a vertical sectional view of another embodiment of capsule in accordance with the present invention;

[0015] 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;

[0016] 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;

[0017] Figure 4(a) is a vertical sectional view of another embodiment of capsule in accordance with the present invention;

[0018] Figure 4(b) is a perspective view of a conical insert for use with the capsule shown in Figure 4(a);

[0019] Figure 5 is a vertical sectional view of another embodiment of capsule in accordance with the present invention;

[0020] Figure 6 is a vertical sectional view of another embodiment of capsule in accordance with the present invention;

[0021] Figure 7 is a schematic enlarged sectional view of the dispensing system for the capsule shown in Figure 6;

[0022] Figure 8 is a vertical sectional view of another embodiment of capsule in accordance with the present invention;

[0023] Figure 9(a) is a bottom view of the capsule of Figure 8; [0024] Figure 9(b) is a bottom view of an alternate embodiment of the capsule of Figure 8;

[0025] Figure 9(c) is a bottom view of an alternate embodiment of the capsule of Figure 8;

[0026] Figure 10 is a side perspective view of another embodiment of capsule in accordance with the present invention;

[0027] Figure 11(a) is a top view of the capsule of Figure 10 with the cover, filter and ingredients removed;

[0028] Figure 11(b) is a top view of an alternative embodiment of the capsule of Figure 10 with the cover, filter and ingredients removed;

[0029] Figure 12 is a sectional view of the capsule of Figure 10 along lines

12- 12;

[0030] Figure 13 is a sectional view of the capsule of Figure 10 along lines

13- 13; and

[0031] Figure 14 is a bottom view of the capsule of Figure 10.

DESCRIPTION OF VARIOUS EMBODIMENTS

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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 cover 18, and adapted to pierce body 12 and interact with machine 20 to inject fluid into capsule 10.

[0036] 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 24a, such as a hollow probe, that is adapted to pierce capsule 10 to dispense a prepared product from capsule 10. [0037] Probe 24a may be adapted to pierce end wall 32 of capsule 10. Dispensing system 24 may further include a collection chamber 24b and exit port 24c, downstream from probe 24a for collecting and dispensing prepared product into receptacle 26.

[0038] Probe 24a 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 24a (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.

[0039] 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. It may also be desirable to avoid interaction with probe 24a 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 24a 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.

[0040] 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. [0041] An opening 36 is defined at one end of body 12 and a flange 38 extends around the perimeter of opening 36.

[0042] 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).

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] 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 ^tm 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 pm, more preferably 20-80 pm and most preferably 30-70 pm.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] Alternative embodiments of capsule 10 are described with reference to Figures 2-14 below. Similar reference numerals are used to refer to similar elements as the embodiment discussed above.

[0054] 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. [0055] Referring to Figures 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 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.

[0056] 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.

[0057] 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.

[0058] 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. [0059] 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 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.

[0060] 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.

[0061] 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.

[0062] 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 0.

[0063] Referring to Figures 8-9(c), another embodiment of capsule 10 is shown. In this embodiment, capsule 10 has a similar construction to the capsule depicted in Figures 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.

[0064] 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's receptacle 26.

[0065] 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.

[0066] 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 100a for adhering the portion of cover 44 that one wishes to remain adhered to end wall 32 and a relatively weaker second adhesive 100b 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 figures 9(a) and 9(b).

[0067] Alternatively, referring to Figure 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.

[0068] Referring to Figures 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.

[0069] Capsule 10 further includes a void 120 that is adapted to receive probe 24a 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 24a 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.

[0070] In one embodiment, as shown in Figure 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 figure 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.

[0071] As shown in Figures 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.

[0072] Capsule 10 further includes aperture 40 and aperture cover 44 such as described above with reference to figures 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.

[0073] 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's receptacle 26.

[0074] 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.