Multicompartment capsules of a beverage forming apparatus and methods of making thereof

Abstract

A multicompartment capsule for use with a beverage forming apparatus includes a base and a sidewall extending upwardly from the base. The sidewall includes a rim extending outwardly from an upper end thereof. The rim surrounds an opening of the multicompartment capsule wherein an upper surface of the outwardly extending rim is sealed to a lower surface of a lid. At least one partition extends through an interior of the multicompartment capsule so as to form a first sealed compartment that is fluidly isolated from a second sealed compartment. The first sealed compartment includes a first beverage formulation and the second sealed compartment includes a second beverage formulation. The first beverage formulation is reactive with the second beverage formulation and the partition separates the first beverage formulation from the second beverage formulation to extend the shelf life of the multicompartment capsule.

We claim: 
     
         1 . A multicompartment capsule for use with a beverage forming apparatus, comprising:
 a base and a sidewall extending upwardly from the base wherein the sidewall includes a rim extending outwardly from an upper end thereof which surrounds an opening of the multicompartment capsule wherein an upper surface of the outwardly extending rim is sealed to a lower surface of a lid; and   at least one partition extending through an interior of the multicompartment capsule so as to form a first sealed compartment that is fluidly isolated from a second sealed compartment wherein the first sealed compartment includes a first beverage formulation and the second sealed compartment includes a second beverage formulation wherein the first beverage formulation is reactive with the second beverage formulation and the partition separates the first beverage formulation from the second beverage formulation to extend the shelf life of the multicompartment capsule.   
     
     
         2 . The multicompartment capsule of  claim 1 , wherein:
 (a) the at least one partition forms a hermetic seal between the first and second compartments;   (b) the at least one partition is a horizontal partition that vertically separates the first sealed compartment from the second sealed compartment wherein an outer perimeter of the horizontal partition is sealed to the sidewall;   (c) the at least one partition is a vertical partition having an upper end sealed to a lower surface of the lid and a lower end sealed to the base of the multicompartment capsule;   (d) the at least one partition is a diagonal partition; or   (e) the at least one partition is a flexible partition that is supported by the lid of the multicompartment capsule.   
     
     
         3 . The multicompartment capsule of  claim 1 , wherein:
 (a) the at least one partition is a thermally detachable partition that is configured to be detached upon heating thereof by a beverage forming apparatus;   (b) the sidewall includes at least one catch and the at least one partition is a thermally detachable partition that is configured to be detached upon heating thereof by a beverage forming apparatus such that the first and second beverage formulations may be combined, the at least one catch configured to obstruct the detached thermally detachable partition such that the thermally detachable partition does not obstruct an outlet formed in the multicompartment capsule during beverage formation;   (c) the at least one partition includes a weakened portion that is configured to rupture under a predetermined pressure build-up in the multicompartment capsule;   (d) the at least one partition includes a first partition and a second partition, wherein the first partition fluidly isolates the first compartment from second compartment and the second partition fluidly isolates the second compartment from a third compartment; or   (e) the at least one partition is friction fit in the multicompartment capsule wherein the partition is configured to be detached when urged by a liquid supplying piercing element of a beverage forming apparatus such that the beverage formulation in the first sealed compartment combines with the beverage formulation in the second sealed compartment.   
     
     
         4 . The multicompartment capsule of  claim 1 , wherein:
 (a) the at least one partition includes a counterweight, the counterweight configured to bias the partition about a protrusion extending upwardly from the base of the multicompartment capsule when the partition is detached in the multicompartment capsule;   (b) the at least one partition extends upwardly from the base so as to seal against a lower surface of the lid;   (c) the at least one partition includes a first thermally detachable partition and a second thermally detachable partition, wherein the first thermally detachable partition fluidly isolates the first compartment from the second compartment and the second thermally detachable partition fluidly isolates the second compartment from a third compartment that includes a third beverage formulation that is reactive with either the first or second beverage formulation wherein the first and second thermally detachable partitions are configured to be detached upon heating thereof by a beverage forming apparatus;   (d) wherein the sidewall includes at least one first catch on an inner surface of the sidewall and at least one second catch on an inner surface of the sidewall and the at least one partition includes a first thermally detachable partition and a second thermally detachable partition, wherein the first thermally detachable partition fluidly isolates the first compartment from the second compartment and the second thermally detachable partition fluidly isolates the second compartment from a third compartment that includes a third beverage formulation therein that is reactive with either the first or second beverage formulations wherein the first and second thermally detachable partitions are configured to be detached upon heating thereof by a beverage forming apparatus such that the first and second thermally detachable partitions travel downwardly and the at least one first catch obstructs an edge of the first thermally detachable partition and the at least one second catch obstructs an edge of the second thermally detachable partition such that the first, second, and third beverage formulations are combined and the detached first and second partitions do not obstruct an outlet of the multicompartment capsule; or   (e) the at least one partition is a thermally detachable partition that is configured to be detached upon heating thereof by a beverage forming apparatus wherein the thermally detachable partition is formed of carnauba wax.   
     
     
         5 . The multicompartment capsule of  claim 1 , wherein the at least one partition is a detachable partition such that the first and second beverage formulations can be combined in the multicompartment capsule and the base including at least one upwardly extending protrusion that is configured to prevent the partition from obstructing an outlet of the multicompartment capsule when the partition is detached. 
     
     
         6 . The multicompartment capsule of  claim 1 , wherein the at least one partition is a thermally detachable partition that is configured to be detached upon heating thereof by a beverage forming apparatus such that the first and second beverage formulations may be combined, the base including at least one upwardly extending protrusion that is configured to prevent the thermally detachable partition from obstructing an outlet of the multicompartment capsule when the partition is detached. 
     
     
         7 . The multicompartment capsule of  claim 1 , wherein the at least one partition includes a first thermally detachable partition and a second thermally detachable partition, wherein the first thermally detachable partition fluidly isolates the first compartment from the second compartment and the second thermally detachable partition fluidly isolates the second compartment from a third compartment that includes a third beverage formulation therein that is reactive with either the first or second beverage formulations wherein the first and second thermally detachable partitions are configured to be detached upon heating thereof by a beverage forming apparatus such that the first and second thermally detachable partitions travel downwardly when detached wherein the base includes at least one upwardly extending protrusion that is configured to prevent the first thermally detachable partition from obstructing an outlet of the multicompartment capsule and the first thermally detachable partition includes an upwardly extending protrusion that is configured to bias the second thermally detachable partition so as to facilitate mixing of the first, second, and third beverage formulations when the first and second thermally detachable partitions are detached. 
     
     
         8 . The multicompartment capsule of  claim 1 , wherein the lid includes at least one puncture element extending downwardly from an inner surface thereof, the puncture element configured to rupture the at least one partition when a liquid supplying piercing element is inserted through the lid such that the first and second beverage formulations can be combined. 
     
     
         9 . The multicompartment capsule of  claim 1 , wherein
 (a) the base is circular, rectangular, or oval shaped and the sidewall is a contoured sidewall that includes one or more upwardly extending sections, one or more outwardly extending sections, and/or one or more upwardly and outwardly extending sections; or   (b) wherein the base is circular, rectangular, or oval shaped and the upwardly extending side wall extends upwardly and outwardly from the base along a first portion, upwardly from an upper end of the first portion along a second portion, and upwardly and outwardly from an upper end of the second portion along a third portion, wherein the outwardly extending rim extends outwardly from an upper end of the third portion.   
     
     
         10 . A method of making a multi-compartment capsule for use with a beverage forming apparatus, the method comprising:
 providing a sheet of thermoformable material to a thermo-forming apparatus;   thermoforming the sheet of thermoformable material so as to form at least one group of compartments wherein each group of compartments includes at least a first compartment having a base and an upwardly extending sidewall and a second compartment having a base and a downwardly extending sidewall;   cutting the thermoformed sheet so as to separate a single group of compartments wherein the cutting forms a first compartment rim that extends outwardly from an upper end of the sidewall of the first compartment and a second compartment rim that extends outwardly from a lower end of the sidewall of the second compartment;   filling an interior of a first compartment with a predetermined quantity of a first beverage formulation;   folding the second compartment at a foldable portion between the first and second compartments so as to locate the base and a portion of the sidewall of the second compartment in an interior of the first compartment;   filling the interior of the second compartment with a predetermined quantity of a second beverage formulation; and   sealing the first and second compartments so as to fluidly isolate the first compartment from the second compartment to make a multi-compartment capsule.   
     
     
         11 . The method of  claim 10 , further comprising depositing one or more layers of material on the thermoformable material wherein;
 (a) the one or more layers includes a barrier coating of polypropylene (PP), ethylene vinyl alcohol (EVOH), polyethylene naphthalate (PEN), or an acrylonitrile copolymer; or   (b) the depositing of the one or more layers produces regions of varying thickness across the thermoformable material.   
     
     
         12 . The method of  claim 10 , wherein the sealing is performed by heat sealing, ultrasonic sealing, welding, or applying an adhesive to the respective sealed surfaces. 
     
     
         13 . The method of  claim 10 , wherein the thermoforming step further includes forming a third compartment of the at least one group of compartments wherein the third compartment includes a base and an upwardly extending sidewall; the cutting step further includes forming at third compartment rim that extends outwardly from an upper end of the sidewall of the third compartment; and the method further comprising folding the third compartment at a foldable portion between the second and third compartments so as to locate the base and a portion of the sidewall of the third compartment in the interior of the second compartment; filling the interior of the third compartment with a predetermined quantity of a third beverage formulation; and sealing the third compartment so as to fluidly isolate the third compartment from the first and second compartments. 
     
     
         14 . The method of  claim 13 , wherein the depositing of the one or more layers produces regions of varying thickness across the thermoformable material including at least one region of a first thickness, at least one region of a second thickness that is less than the thickness of the first region, at least one third region of a third thickness that is less than the thickness of the second region, and at least one optional fourth region of a fourth thickness that can have a thickness equal to or less than thickness the first region, a thickness equal to or less than the thickness of the second region, or a thickness equal to or less than the thickness of the third region and the thermoforming includes forming at least one first compartment in the first region, at least one second compartment in the second region, at least one third compartment in the third region and an option lid in the optional fourth region. 
     
     
         15 . A capsule receptacle of a beverage forming apparatus, that is operable to receive a multicompartment capsule, the receptacle comprising:
 a base and a lid, wherein the base includes a cavity therein that is shaped to receive a multicompartment capsule and the lid is operable to seal the multicompartment capsule in the cavity; and   a spot heater operable to heat a portion of a surface of the cavity wherein the heated surface is configured to be adjacent a thermally detachable partition included in the interior of a multicompartment capsule wherein the multicompartment capsule is configured to fit in the cavity such that the spot heater is operable to detach a portion of the thermally detachable partition.   
     
     
         16 . The capsule receptacle of  claim 15 , wherein:
 (a) the spot heater is a ring heater configured to surround a sidewall of the multicompartment capsule;   (b) the spot heater is adjacent a sidewall in the base defining the cavity;   (c) an insulator is arranged in the base to prevent spreading of heat generated by the spot heater; or   (d) the spot heater includes at least a first ring heater configured to surround a sidewall of the multicompartment capsule and a second ring heater configured to surround a sidewall of the multicompartment capsule below the first ring heater.   
     
     
         17 . The capsule receptacle of  claim 15 , wherein
 (a) a shelf surrounds an opening of the cavity wherein an outwardly extending rim of the multicompartment capsule is configured to be supported by the shelf when the multicompartment capsule is received in the cavity;   (b) a lower gasket is included in the cavity, the lower gasket configured to seal against a lower surface or lower outer surface of the multicompartment capsule so as to form a pressure and fluid tight seal;   (c) an upper gasket included in the cavity, the upper gasket configured to seal against the shelf and a lower surface of the lid of the receptacle so as to form a pressure and fluid tight seal; or   (d) an upper gasket included in the cavity, the upper gasket configured to seal against an upper surface of a lid of the multicompartment capsule included in the cavity and the lid of the capsule.   
     
     
         18 . A beverage forming apparatus including capsule receptacle of  claim 15 . 
     
     
         19 . A method of forming a beverage with a multicompartment capsule included in the beverage forming apparatus of  claim 15 , the multicompartment capsule including at least first and second compartments which are fluidly isolated wherein the first compartment includes a first beverage formulation and the second compartment includes a second beverage formulation and the first and second compartments are separated by a thermally detachable partition, the method comprising:
 heating a surface of the cavity that is in thermal contact with the thermally detachable partition through a base, lid, or sidewall of the multicompartment capsule so as to detach a portion of the thermally detachable partition such that the first compartment is not fluidly isolated from the second compartment;   combining the first beverage formulation with the second beverage formulation and fluid supplied by beverage forming apparatus; and   dispensing the combined first beverage formulation, second beverage formulation, and fluid into a vessel so as to form the beverage.   
     
     
         20 . The method of  claim 19 , wherein the heated surface is an annular surface and the thermally detachable partition is sealed to an inner surface of the sidewall of the multicompartment capsule, the method further comprising heating the thermally detachable partition around a perimeter thereof to a temperature sufficient to detach the thermally detachable partition from the sidewall.