U.S. patent application number 16/414816 was filed with the patent office on 2019-10-24 for capsule with steeping chamber.
The applicant listed for this patent is 2266170 Ontario Inc.. Invention is credited to Yucheng Fu, Shelby Parkinson, Liberatore A. Trombetta.
Application Number | 20190322447 16/414816 |
Document ID | / |
Family ID | 54143590 |
Filed Date | 2019-10-24 |
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United States Patent
Application |
20190322447 |
Kind Code |
A1 |
Trombetta; Liberatore A. ;
et al. |
October 24, 2019 |
Capsule With Steeping Chamber
Abstract
A capsule, for use in a machine for preparing consumable
products from capsules includes a body defining an interior space
with an opening. A cover is disposed over the opening. A filter is
disposed in the interior space to define a chamber between the
filter and the cover. Ingredients are disposed in the chamber for
preparing a desired product with at least 50% of the ingredients
having a particulate size greater than a #16 mesh.
Inventors: |
Trombetta; Liberatore A.;
(Ancaster, CA) ; Fu; Yucheng; (Mississauga,
CA) ; Parkinson; Shelby; (Paris, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
2266170 Ontario Inc. |
Mississauga |
|
CA |
|
|
Family ID: |
54143590 |
Appl. No.: |
16/414816 |
Filed: |
May 17, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15127528 |
Sep 20, 2016 |
10336531 |
|
|
PCT/CA2015/050214 |
Mar 20, 2015 |
|
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16414816 |
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|
61968843 |
Mar 21, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 85/8046 20130101;
B65D 85/8043 20130101 |
International
Class: |
B65D 85/804 20060101
B65D085/804 |
Claims
1. 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; a cover disposed over said opening;
a filter disposed in said interior space to define a chamber
between said filter and said cover; and ingredients disposed in
said chamber for preparing a desired product, at least 50% of said
ingredients having a particulate size greater than a #16 mesh.
2. The capsule of claim 1, further comprising a second filter
disposed in said chamber.
3. The capsule of claim 2, wherein said second filter defines a
first ingredients chamber that is adapted to contain a subset of
said ingredients.
4. The capsule of claim 3, wherein said cover is transparent and
wherein said first ingredients chamber is disposed proximate to
said transparent cover.
5. The capsule of claim 1, wherein said filter has an average fluid
flow rate that is in the range of 50% to 90% of the average fluid
flow rate for fluid being injected into said capsule.
6. The capsule of claim 1, wherein said chamber has a volume that
is at least 90% filled by said ingredients.
7. The capsule of claim 1, wherein said ingredients are selected
from tea, herbs, spices, fruits and flowers.
8. The capsule of claim 1, wherein said ingredients may be viewed
through said cover prior to use of said capsule in said
machine.
9. The capsule of claim 1, further comprising a second filter
disposed in said chamber.
10. The capsule of claim 9, wherein said second filter defines a
first ingredients chamber that is adapted to contain a subset of
said ingredients.
11. The capsule of claim 10, wherein said cover is transparent and
wherein said first ingredients chamber is disposed proximate to
said transparent cover.
12. A capsule, for use in a machine for preparing consumable
products from capsules, said machine having an injection system
that includes at least one injection nozzle for injecting heated
fluid into said capsule at a predetermined flow rate, said capsule
comprising: a cover and a filter defining a steeping chamber; said
cover being formed of a material that is heat shrinkable and
resistant to tearing so as to shrink sufficiently around said at
least one injection nozzle; when said at least one injection nozzle
pierces said cover and injects heated fluid into said capsule, to
create a seal that allows pressure to build within said steeping
chamber up to a maximum pressure; said filter being formed of one
or more materials that are sufficiently phobic to said heated fluid
to cause said steeping chamber to fill with fluid without exceeding
said maximum pressure; and ingredients disposed in said steeping
chamber for preparing a desired product, wherein said filter is
constructed and arranged to restrict a flow of the fluid through
said filter to optimize extraction or infusion of said ingredients
disposed within said steeping chamber.
13. The capsule as claimed in claim 12, wherein said filter is
secured to said cover.
14. The capsule as claimed in claim 12, further comprising a body
defining a flange for supporting said capsule within the
machine.
15. The capsule of claim 12, wherein said filter has an average
fluid flow rate that is in the range of 50% to 90% of the average
fluid flow rate for fluid being injected into said capsule.
16. The capsule of claim 12 wherein said steeping chamber has a
volume that is at least 90% filled by said ingredients.
17. A capsule, for use in a machine for preparing consumable
products from capsules, said machine having a system for injecting
heated fluid into said capsule at a predetermined flow rate, said
capsule comprising: a filter defining a steeping chamber; said
filter being formed of one or more materials that are sufficiently
phobic to the heated fluid injected into said capsule to allow said
steeping chamber to fill with fluid and pressure to build within
said steeping chamber up to a maximum pressure; and ingredients
disposed in said steeping chamber for preparing a desired product,
wherein said filter is constructed and arranged to restrict a flow
of the fluid through said filter to optimize extraction or infusion
of said ingredients disposed within said steeping chamber.
18. The capsule of claim 17, wherein said filter has an average
fluid flow rate that is in the range of 50% to 90% of the average
fluid flow rate for fluid being injected into said capsule.
19. The capsule of claim 17 wherein said steeping chamber has a
volume that is at least 90% filled by said ingredients.
20. The capsule of claim 17 wherein said filter includes one or
more high flow zones that allow a higher rate of fluid flow
compared to the remainder of said filter.
Description
[0001] This application is a continuation of U.S. application Ser.
No. 15/127,528 filed on Sep. 20, 2016, which is a 371 of
international Application No. PCT/CA2015/050214 filed on Mar. 20,
2015, which claims the benefit of U.S. provisional Application No.
61/968,843 filed on Mar. 21, 2014.
FIELD
[0002] This specification relates to capsules for preparing
consumable products using capsule machines, and in particular to
capsules adapted to provide improved conditions for preparing a
steeped consumable product in a capsule machine.
BACKGROUND
[0003] 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.
[0004] Single serve capsules adapted for use in machines to prepare
a desired consumable product are becoming increasingly popular.
Such capsules come in a variety of formats for producing consumable
products such as coffee, tea or hot chocolate.
[0005] In North America, a leading provider of capsules and capsule
machines is Keurig Green Mountain Inc. This company produces
K-Cup.TM. capsules and Keurig.TM. capsule machines (also known as
brewers). K-Cup.TM. capsules have a first chamber defined by a
paper filter that is loosely packed with ingredients (such as
ground coffee) and a second chamber downstream of the first chamber
that defines an empty space for receiving a prepared product that
flows through the paper filter prior to dispensing into a cup.
[0006] A predetermined volume of heated water is injected by a
Keurig.TM. machine into the first chamber of a K-cup.TM. coffee
capsule at a predetermined flow rate. The heated water flows
through the ingredients in the capsule and contacts the paper
filter. The bottom portion of the paper filter quickly becomes
saturated and allows the prepared product to flow through the
filter at substantially the same flow rate as fluid enters the
capsule. As a result, the fluid tends to continuously flow through
the ingredients with less than optimum mixing and extraction. It
has been found that ingredients in K-cup.TM. capsules used in
Keurig.TM. machines are not optimally saturated other than
ingredients disposed along the central fluid flow path of the
capsule. Nonetheless, K-cup.TM. capsules remain a leading brand of
capsules in the North American single serve coffee market.
[0007] The optimum conditions for preparing drip-style coffee
differ from the optimum conditions for preparing other forms of
consumable products. For example, certain consumable products, such
as whole leaf tea products, benefit from soaking or steeping (the
term steeping will be used hereafter) the precursor ingredients in
a fluid, such as heated water, for a desired period of time prior
to dispensing into a user's cup.TM.. Such products often also
benefit from a mixing or turbulence of the precursor ingredients
within the fluid during the steeping phase.
[0008] A problem with conventional capsules and capsule machines
such as the K-cup.TM. capsules and Keurig.TM. machines is that
their structure and operations are designed primarily for the
purpose of preparing drip-style filtered coffee. This problem is
exasperated by the desire to produce a prepared beverage in a
relatively short time frame (60 seconds or less) thus requiring
fluid to be injected into the machine at a relatively high flow
rate.
[0009] This problem could be addressed by designing capsule
machines that provide optimum conditions for preparing a steeped
consumable product. This does not provide a solution for consumers
who desire a shorter preparation time or who already own a
conventional capsule machine and wish to avoid acquiring a new
appliance however.
[0010] There is a need for a capsule that is adapted to provide
improved conditions for preparing a steeped consumable product.
There is also a need for such a capsule to be used with
conventional capsule machines.
SUMMARY
[0011] In one aspect the invention provides a capsule, for use in a
machine for preparing consumable products from capsules, said
machine having an injection system that includes at least one
injection nozzle for injecting heated fluid into said capsule at a
predetermined flow rate, said capsule comprising:
[0012] a body defining an interior space with an opening;
[0013] a cover disposed over said opening, said cover being formed
of a material that is resistant to tearing and adapted to shrink
sufficiently around said at least one injection nozzle when said at
least one injection nozzle pierces said cover and injects heated
fluid into said capsule to create a seal that allows pressure to
build within said interior space beneath said cover up to a maximum
pressure;
[0014] a filter disposed in said interior space to define a
steeping chamber between said filter and said cover, said filter
being formed of one or more materials that are sufficiently phobic
to said heated fluid to cause said steeping chamber to fill with
fluid without exceeding said maximum pressure; and
[0015] ingredients disposed in said interior space for preparing a
desired product.
[0016] In another aspect, the invention provides a capsule, for use
in a machine for preparing consumable products from capsules, said
capsule comprising:
[0017] a body defining an interior space with an opening;
[0018] a cover disposed over said opening;
[0019] a filter disposed in said interior space to define a chamber
between said filter and said cover; and
[0020] ingredients disposed in said chamber for preparing a desired
product, at least 50% of said ingredients having a particulate size
greater than a #16 mesh.
[0021] 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
[0022] 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.
[0023] FIG. 1 is a sectional view of a capsule in accordance with
one aspect of the present invention disposed within a schematic
representation of a machine for preparing consumable products from
capsules;
[0024] FIG. 2 is an enlarged sectional view of the capsule of FIG.
1 during use in the capsule machine;
[0025] FIG. 3 is a sectional view of a capsule in accordance with
another aspect of the present invention;
[0026] FIGS. 4A-4H are schematic sectional views of the capsule and
machine of FIG. 1 during consecutive stages of the process for
preparing a consumable product.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0027] 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.
[0028] A capsule in accordance with the present invention is shown
generally at 10 in the Figures. Capsule 10 includes a body 12,
filter 14, ingredients 16 and cover 18. Body 12 and cover 18 are
each preferably formed of multilayered materials that include one
or more barrier layers providing barriers against one or more
environmental factors such as light, oxygen, and moisture. Capsule
10 may be sized to provide a single serving of a desired product or
multiple servings.
[0029] Capsule 10 is sized and configured for use in a machine 20
that is adapted for preparing a product from capsule 10.
[0030] Machine 20 includes an injection system 22 for injecting a
fluid, typically heated water, into the capsule 10 for mixing with
ingredients 16. Injection system 22 may include at least one
injection nozzle 22a disposed on machine 20 that is adapted to
pierce cover 18 to inject fluid into capsule 10. In an alternative
embodiment (not shown), injection system 22 may have at least one
component disposed on capsule 10, such as on body 12 beneath cover
18, and adapted to pierce cover 18 and interact with other
components of injection system 22 on machine 20 to inject fluid
into capsule 10.
[0031] Machine also includes a dispensing system 24 for dispensing
product from capsule 10 into a desired receptacle 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.
[0032] Body 12 of capsule 10 includes a sidewall 30 and an end wall
32 together defining an interior space 34. Interior space 34
preferably has a volume in the range of 30 cc to 100 cc for
preparing a single serving of beverage and more preferably a volume
in the range of 40 cc to 80 cc.
[0033] 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. Filter 14 may be
secured to flange 38 or to an interior surface of capsule 10 (such
as to sidewall 30 or the underside of cover 18).
[0034] In another embodiment (not shown), 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 or
underside of cover 18.
[0035] Cover 18 is disposed over opening 36 and secured to body 12
such as by sealing cover 18 directly to flange 38 or by sealing
cover 18 to filter 14 which in turn is sealed to flange 38. Cover
18 may be transparent in order that ingredients 16 may be viewed
through cover 18 prior to use of capsule 10 in machine 20.
[0036] Cover 18 is formed of a material that is resistant to
tearing and adapted to shrink upon exposure to heat. Cover 18 is
thus adapted to shrink around the opening formed in cover 18 by
injection system 22 to form a sufficient seal to withstand the
buildup in pressure within capsule 10 under normal conditions
during use in machine 20. In other words, cover 18 is adapted to
shrink sufficiently around the at least one injection nozzle when
the at least one injection nozzle pierces the cover and injects
heated fluid into the capsule to create a seal and allow the
buildup in pressure within capsule up to a maximum pressure.
[0037] Preferably, cover 18 is formed of a multi-layered material
having a minimum tensile strength of 3000 psi and a minimum
elongation of 50%. Preferably cover 18 includes polymer materials,
more preferably cover 18 comprises at least 50% polymer materials
and most preferably cover 18 comprises at least 75% polymer
materials.
[0038] Examples of suitable materials for cover 18 include
polyethylene (PE), polyethylene terephthalate (PET) and polyamide
PA6. A multi-layered material for cover 18 may include at least one
layer formed of a continuous film of tear resistant and heat
shrinkable material (laminated or extrusion coated) or a
non-continuous film such as a non-woven polymer, mesh or perforated
film. Examples of a multi-layered material for cover 18 include
(from outside layer to inside layer): PET/aluminum foil/PE,
PET/EVOH/PE, PET/metalized PET/PE or PET/PE. It has been found that
formation of cover 18 from a multilayered PET/PE or PET/EVOH/PE
material comprising at least 90% polymer materials provides
preferred sealing performance around injection system 22.
[0039] A steeping chamber 40 is defined within interior space 34 of
capsule 10 between cover 18 and filter 14. Steeping chamber 40 has
a volume V1 that is adapted to contain a sufficient volume V2 of
ingredients 16 to produce a desired consumable product using
machine 20. Ingredients 16 that are disposed in steeping chamber
40, as described further below, are preferably selected for optimum
extraction under the conditions within steeping chamber 40 during
use of machine 20.
[0040] For the embodiment depicted in FIGS. 1 and 2, the volume V2
of ingredients 16 is no less than 50% of the volume V1 of steeping
chamber 40, more preferably no less than 70% and most preferably no
less than 90% so that ingredients are easily visible through a
transparent cover 18.
[0041] Filter 14 has an average fluid flow rate F1 that is less
than the average fluid flow rate F2 of injection system 22.
Preferably, the average fluid flow rate F1 of filter 14 is between
50% and 90% of the average fluid flow rate F2 of injection system
22, more preferably between 55% and 80% and most preferably between
60% and 75%.
[0042] The average fluid flow rates F1 and F2 noted above are
determined over the course of the product preparation process using
machine 20 in accordance with the test procedure below. An empty
capsule 10 containing no filter 14 and no ingredients 16 is
disposed in machine 20 and machine 20 is activated to prepare a
product of a selected size. The weight of the product prepared by
the machine 20 is measured as well as the time required to prepare
the product from the moment machine 20 is activated to the moment
the flow of prepared product has stopped. The measured weight per
unit of time is deemed to be the fluid flow rate F2 for injection
system 22. The first capsule is removed and an empty capsule 10
with a filter 14 (but no ingredients 16) is then disposed in same
machine 20 and machine 20 is activated to prepare a product of the
same selected size. The weight of the product prepared by machine
20 is measured as well as the time required to prepare the product
from the moment machine 20 is activated to the moment the flow of
prepared product has stopped. The measured weight per unit of time
is deemed to be the fluid flow rate F1 for filter 14.
[0043] Filter 14 may have a uniform fluid flow rate F1 over its
entire surface area within interior space 34 or it may be adapted
to provide zones 42 having different rates of fluid flow. Filter 14
may thus be adapted to provide one or more high flow zones 42a that
allow a relatively higher rate of fluid flow as compared to the
remainder of filter 14. Conversely, filter 14 may be adapted to
provide one or more low flow zones 42b that allow a relatively low
rate of fluid flow as compared to the remainder of filter 14. Zones
42 may also be disposed at desired locations L on filter 14 to
optimize the performance of steeping chamber 40. For example, high
flow zones 42a may be at locations L1 on filter 14 proximate to
cover 18 to allow air to flow in the head space above the fluid to
balance the pressure differential between steeping chamber 40 and
the remainder of capsule 10. Low flow zones 42b may be at locations
L2 along the sides of filter 14 to reduce the fluid flow along such
side portions and thus encourage flow through the bottom portion of
filter 14.
[0044] Filter 14 is also 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.
[0045] Filter 14 preferably has an air permeability of at least 400
L/sm2, more preferably at least 1000 L/sm2 and even more preferably
at least 1800 L/sm2 (all measurements based on ASTM Standard
D737-96 "Standard Test Method for Air Permeability of Textile
Fabrics"). By comparison, the conventional pleated paper filter for
the Keurig K-cup.TM. capsule has a basis weight of 40 grams per
square meter (gsm) and an air permeability of approximately 250
L/sm2.
[0046] Preferably, filter 14 is formed of a non-woven fabric
filtration material such as polyester, polyethylene or nylon
non-woven fabric. The basis weight for filter 14 is in the range of
40 to 150 gsm and more preferably between 70 to 120 gsm.
[0047] 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
.mu.m, more preferably between 40 to 80 .mu.m. More details of a
preferred filtration material for filter 14 are provided in
co-pending patent application Ser. No. 14/074,024 which is
incorporated in its entirety herein by reference.
[0048] Filter 14 may alternatively be formed of a polymer sheet,
such as polyester or Nylon, which may be perforated or otherwise
modified to define channels. The size and distribution of openings
are optimized in a way that is resistant to water exiting.
[0049] Filter 14 may alternatively be formed from an ultra high
molecular weight polyethylene (UHWMPE) which is also a filter
material due to the cavities/pores formed during
polymerization.
[0050] Filter 14 may alternatively be formed from modified filter
paper with a phobic coating to achieve the fluid resistant
property. Preferably, the coating is distributed on filter in a
manner that creates high flow zones and/or low flow zones as
described further below.
[0051] More details of the manner for securing filter 14 and cover
18 to flange 38 of body 12 are provided in co-pending patent
application Ser. No. 13/600,582 which is incorporated in its
entirety herein by reference.
[0052] Cover 18 and filter 14 may be adapted to be removed from
body 12 for instance by separating an integral tab (not shown)
defined in flange 38 and applying a peeling force. More details of
capsules 10 having portions that are removable are provided in
co-pending patent application Ser. No. 14/098,915 which is
incorporated in its entirety herein by reference.
[0053] While filter 14 has an average fluid flow rate F1 over the
course of the product preparation process in machine 20, the fluid
flow rate may vary widely at different times during the process due
to the fluid phobic properties of filter 14. At the beginning of
the product preparation process for example, as steeping chamber 40
is filling with fluid, the phobic properties of filter 14 may
result in little or no fluid flowing through filter 14. This
results in an extended dwell time for ingredients 16 and fluid
within steeping chamber 40. Once steeping chamber 40 is filled with
fluid then the fluid flow rate of filter 14 may increase as fluid
continues to flow into steeping chamber 40 through injection system
22 and as the surface tension of fluid is broken and fluid is
forced to flow through filter 14. Certain machines 20 may further
include a pulse cycle that varies the timing and/or amount of fluid
that is injected into the capsule 10 using injection system 22.
[0054] The phobic properties of filter 14 are adapted to restrict
the flow of fluid through capsule 10 by a sufficient amount within
the operational constraints of machine 20 to optimize the
extraction or infusion of ingredients 16 disposed within steeping
chamber 40. As described further below, once steeping chamber 40 is
filled with fluid, the pressure within steeping chamber 40 will
increase as the fluid continues to flow into steeping chamber 40
through injection system 22. The increase in pressure within
steeping chamber 40 is believed to further enhance the process of
extraction or infusion of ingredients 16 disposed within steeping
chamber 40. Also, extracts from ingredients 16 such as aroma and
taste compounds, lipid and functional compounds may act to reduce
the surface tension of fluid to further permit flow through filter
14.
[0055] A steeping chamber 40 having a greater volume V1 will take a
greater period of time in a machine 20 to fill with fluid before
pressure builds up within steeping chamber 40. A steeping chamber
40 having a lesser volume V1 will conversely take a lesser period
of time to fill with fluid and thus will build up pressure sooner
and to a greater extent as fluid continues to flow into steeping
chamber 40. It has been found that a lesser volume V1 is preferred
for optimum performance of steeping chamber 40.
[0056] Ingredients 16 that are disposed in steeping chamber 40 may
include insoluble ingredients 16 such as tea leaves, coffee
grounds, herbs, spices or other ingredients adapted for forming a
consumable product by extraction or infusion. Additional
ingredients 16 may be disposed either in steeping chamber 40 or
elsewhere in interior space 34. Such additional ingredients 16 may
include soluble ingredients 16 such as coffee, chocolate, soup
stock, flavor additives or other ingredients in powdered,
crystallized or other forms adapted for solubility or contained
within a soluble film or pouch. Additional ingredients 16 may also
include active ingredients (e.g. foaming agents), natural health
additives, regulated drugs, alcohol or other soluble or insoluble
ingredients.
[0057] One or more ingredients 16 may include sensory attributes
that are desirable to convey to a consumer or end user prior to the
preparation of the consumable product. For example, ingredients 16
may include soluble or insoluble ingredients having visual
attributes that may be of interest to a consumer. Examples of
ingredients 16 with visual attributes include whole tea leaves,
florets, pieces of dried fruit, vegetables, herbs, nuts or beans,
pieces of chocolate, spices (such as cloves or cinnamon sticks),
natural health additives (e.g. gogi berries), dried pieces of meat
(e.g. shrimp), tofu, vegetables or noodles for soup.
[0058] In a preferred embodiment, ingredients 16 include a subset
of ingredients having irregular shapes and/or relatively large
particulate sizes such as one or more of whole leaf teas, herbs,
spices, fruits and flowers. Preferably ingredients 16 include a
combination of larger particulate sizes and smaller particulate
sizes. Ingredients having larger particulate sizes may include
whole or substantially whole leaves or other desired portions of
tea, herbs, spices, fruits and flowers. Ingredients having smaller
particulate sizes may include cut, ground, crystallized or
otherwise processed portions of such ingredients. Preferably, at
least 50% of the ingredients comprise ingredients having a
particulate size greater than a #16 mesh (1.18 mm). More
preferably, at least 70% of the ingredients comprise ingredients
having a particulate size greater than a #16 mesh.
[0059] In one embodiment, for single serve capsules 10 having a
volume up to 100 cc, a preferred consumable product having improved
sensory attributes is formed from 1.5 grams to 30 grams of
ingredients 16 comprising one or more of whole leaf teas, herbs,
spices, fruits or flowers as described above in which at least 50%
of ingredients 16 have a particle size of at least 1.18 mm (mesh
#16).
[0060] In other embodiments, multiple filters 14 may be disposed
within interior space 34 of capsule 10. Such filters 14 may be
disposed inside or outside of steeping chamber 40. Additional
filters 14 may have different average fluid flow rates as well as
different degrees of phobicity or non-phobicity to fluid.
[0061] FIG. 3 for example depicts a capsule 10 in accordance with
an alternate embodiment of the invention. The same figure
references are used to identify similar features to the capsule 10
for the embodiment described above.
[0062] Capsule 10 includes a steeping chamber 40 defined between
cover 18 and filter 14a. Filter 14a has fluid phobic properties
similar to those described in the embodiment above. It may be seen
that steeping chamber 40 has a greater volume V1 than the volume V1
for the embodiment of capsule 10 described above. This allows a
longer dwell time before the conditions within steeping chamber 40
cause fluid to flow through filter 14a.
[0063] Capsule 10 further includes a second filter 14b disposed in
steeping chamber 40 above filter 14a. Second filter 14b defines a
first ingredients chamber 44 that is disposed proximate to a
transparent cover 18. Ingredients chamber 44 is adapted to contain
a subset of ingredients 16a that have visual attributes that may be
viewed through transparent cover 18. Additional ingredients 16b are
disposed in steeping chamber 40 outside of first ingredients
chamber 44 (these may include additional insoluble ingredients 16
that may have less desirable visual attributes). Additional
ingredients 16c may also be disposed in interior space 34 outside
of steeping chamber 40 (these may include soluble or active
ingredients 16).
[0064] Referring to FIGS. 4A-4H, a capsule 10, in accordance with
the first embodiment depicted in FIGS. 1 and 2, is shown during
different stages of the process for preparing a consumable product
from the capsule 10. FIG. 4A shows capsule 10 disposed in machine
20 prior to activation of the product preparation process. FIG. 4B
shows an injection nozzle 22a for injection system 22 piercing
cover 18 of capsule 10 and a dispensing nozzle 24a for dispensing
system 24 piercing end wall 32 of capsule 10. FIG. 4C shows fluid
(heated water) being injected into steeping chamber 40 of capsule
10. FIG. 4D shows fluid (heated water and extract from ingredients
16) collecting within steeping chamber 40 due to the phobic
properties of filter 14. FIG. 4E shows steeping chamber 40 filled
with fluid (heated water and extract from ingredients 16) and fluid
(heated water and extract from ingredients 16) passing through
filter 14 of capsule 10 for dispensing through dispensing system
24. It can be seen in FIG. 4E that cover 18 bulges upwardly away
from steeping chamber 40 due to the higher pressure within steeping
chamber 40 as fluid continues to enter steeping chamber 40 at a
higher rate than fluid exits through filter 14. FIG. 4F shows the
fluid level within steeping chamber 40 dropping as the flow rate of
fluid entering steeping chamber 40 through injection system 22
subsides. FIG. 4G shows the fluid level within steeping chamber 40
continuing to drop as a blast of air is injected into steeping
chamber 40 through injection system 22 to complete the product
preparation process. FIG. 4H shows capsule 10 following completion
of the product preparation process with little or no fluid
remaining in capsule 10 and fully saturated ingredients 16 disposed
in steeping chamber 40.
[0065] 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.
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