Beverage tablets and methods of forming beverages from beverage tablets

Abstract

Embodiments disclosed herein relate to beverage tablets. The tablets may have a generally cylindrical intermediate region and first and second ends, where at least one such end may be domed. The tablets may have generally rounded transitions between the generally cylindrical intermediate region and the at least one domed region. The tablets may be coated with a coating. Associated methods of using beverage tablets to produce a brewed beverage are also provided. In use, a beverage tablet may be received into a brew chamber of a beverage machine. The tablet may be wetted to make the coating malleable. The tablet may be compressed and deformed to conform to the shape of the brew chamber and injected with water. The water may flow through the tablet and into a dispensing station, forming a brewed beverage.

Description

BEVERAGE TABLETS AND METHODS OF FORMING BEVERAGES FROM BEVERAGE TABLETSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. provisional application serial number 63 / 564,381, filed March 12, 2024, the disclosure of which is incorporated by reference in its entirety.FIELD

[0002] Disclosed embodiments are related to package-less beverage tablets and methods of forming beverages with package-less beverage tablets.BACKGROUND

[0003] Tablets of compacted beverage ingredients can be used for forming a beverage. In some arrangements, such beverage tablets are mixed directly with hot water to form a beverage. In some arrangements, water is permitted to percolate through beverage tablets to form a beverage.SUMMARY

[0004] A beverage tablet for use with a beverage machine to form a beverage is provided. The beverage tablet comprises a body comprising a first end, a second end, and a cylindrical intermediate region between first and second ends. The first end comprises a domed region. The body further comprises beverage ingredient compacted into a first density. The beverage tablet further comprises at least one coating at least partially covering the compacted beverage ingredient. The at least one coating is configured to be malleable when exposed to liquid to allow for the domed region to be deformed by application of force from a beverage machine in order to conform to a shape of a brew chamber of the beverage machine and form a seal against the brew chamber. The body and the at least one coating are configured to be pierced to allow liquid to flow into the beverage tablet and the at least one coating is configured to be malleable when exposed to liquid to allow for the beverage tablet to be expanded by the liquid to lower the first density of the beverage ingredient to a second density.

[0005] A method of forming a beverage using a beverage tablet, wherein the beverage tablet comprises a body with a first end comprising a domed region, a second end, a cylindrical intermediate region between the first end and second end, and a coating around at least a portionof the body, is provided. The method comprises receiving the beverage tablet into a brew chamber of a beverage machine, introducing water into the brew chamber to wet the beverage tablet and soften the coating, applying a force to the beverage tablet, causing the beverage tablet to deform and conform to a shape of the brew chamber, piercing the first end with at least one inlet needle, introducing a volume of water into the beverage tablet through the at least one inlet needle, and allowing brewed beverage to exit the brew chamber.

[0006] A die assembly for compacting beverage ingredient into a body of a beverage tablet is provided. The die assembly comprises a first die section configured to form a first end of the body, and a second die section configured to form a second end of the body. The first die section comprises a concave section configured to form a domed region of the first end of the body.

[0007] A method of forming a beverage tablet is provided. The beverage tablet is for use with a beverage machine to form a beverage. The method includes compressing a beverage ingredient into a body of a beverage tablet using a die assembly. The die assembly has a first die section that forms a first end of the body, a second die section that forms the second end of the body, and a cylindrical section that forms a cylindrical intermediate region of the body between the first and second ends of the body. The first die section includes a concave section configured to form a domed region of the first end of the body. The method also includes coating at least a portion of the beverage tablet with a coating.

[0008] It should be appreciated that the foregoing concepts, and additional concepts discussed below, may be arranged in any suitable combination, as the present disclosure is not limited in this respect. Further, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various non-limiting embodiments when considered in conjunction with the accompanying figures.BRIEF DESCRIPTION OF DRAWINGS

[0009] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:

[0010] FIG. 1A shows a perspective view of a beverage tablet according to an embodiment;

[0011] FIG. IB shows a side view of the beverage tablet according to the embodiment of FIG. 1A;

[0012] FIGs. 2A-2C show various beverage tablets having different heights according to some embodiments;

[0013] FIGs. 3 A and 3B show various beverage tablets having differently shaped transitions between an intermediate region and first and second ends according to some embodiments;

[0014] FIG. 3C shows a beverage tablet having a generally flat upper and lower surface according to some embodiments.

[0015] FIG. 4 shows a cross-sectional side view of a beverage tablet inserted into a brew chamber of a beverage machine;

[0016] FIG. 5 shows a cross-sectional side view of a compressed beverage tablet in the brew chamber according to the embodiment of FIG. 4;

[0017] FIG. 6 shows a cross-sectional side view of an expanded beverage tablet in the brew chamber according to the embodiment of FIG. 4; and

[0018] FIG. 7 shows a cross-sectional side view of a beverage tablet formed in a die assembly according to an embodiment.DETAILED DESCRIPTION

[0019] Many brewed beverages are conventionally prepared by enclosing an amount of loose particles of beverage ingredient, such a loose coffee grinds or tea leaves, into a brewing machine. Use of loose particles of beverage ingredient to prepare brewed beverages may be inconvenient as it may require additional steps of measuring out a specific amount beverage ingredient. Additionally, loose particles of beverage ingredient carries the risk of spillage while preparing and transporting the desired amount of beverage ingredient to and from the beverage machine. Additionally, many brewing machines that use loose particles of beverage ingredient require cleaning after each use to remove loose particles from the inside of the machine.

[0020] Single serve beverage pods have been implemented to alleviate some of these concerns. However, such beverage pods generally contain loose beverage ingredient in a disposable packaging. Utilizing such packaging may generate additional waste.

[0021] The inventors have therefore recognized benefits of providing package-less beverage consumables that can be used with a beverage machine to form a beverage. In some embodiments, a beverage consumable comprises a tablet which includes beverage ingredient compacted into a desired shape and density. The tablet may be at least partially surrounded by a coating. Such beverage tablets may allow for the increased convenience of single-serve beverage consumables while reducing waste.

[0022] In some embodiments, the beverage ingredients of the beverage tablet have been compacted to form the tablet. The beverage tablet may be able to hold its own shape, and thus may not require individual packaging to prevent dispersing of the beverage material prior to use in forming a beverage. The beverage tablet may be configured to be received within a beveragemachine without packaging such that the beverage ingredients of the beverage tablet directly contact the beverage machine (e.g. a brew chamber) during a brewing process (e.g. without requiring the beverage machine to pierce through or otherwise open packaging to access the beverage ingredients).

[0023] In some embodiments, the beverage tablet comprises a solid body comprising a beverage ingredient. For example, one or more beverage ingredients of the beverage tablet may be formed into a solid body by compression, adhesion, solidification in a mold, or any of a variety of other suitable methods for making a rigid body from one or more beverage ingredients. The use of a rigid body in a beverage ingredient may provide any of a number of advantages, including greater ingredient density, brewing predictability, and tablet formability during manufacturing.

[0024] In some embodiments, a package-less beverage consumable (e.g., a beverage tablet) may include a coating disposed along at least a portion of the outer surface at the periphery of the consumable. In some embodiments, the coating may bind the beverage ingredients within the interior of the consumable. In some embodiments, the beverage ingredients held within the coating may be loose, such as loose ground coffee, or compacted. The coating may be a food grade binder, an alginate, edible, soluble, or any other suitable material. In some embodiments, the coating may serve as a barrier to reduce infiltration of oxygen and / or moisture such as to maintain freshness of the beverage ingredients. Material of the package-less beverage consumable, including a coating of the consumable if one is present, may directly contact some portion of the beverage machine, such as the brew chamber, before brewing the beverage, without intervening packaging in-between.

[0025] As discussed in greater detail below, the inventors have recognized and appreciated that beverage tablets prepared using coatings, including biodegradable coatings, may, in some embodiments, retain all of the advantages of other single- serving beverage packages while reducing beverage ingredient packaging and / or waste resulting from the preparation of a beverage. The coating may provide any of a variety of advantages for labeling of beverage tablets, for retaining beverage ingredients within a beverage tablet, and / or for beverage ingredient preservation. The coating may be biodegradable, e.g., to further reduce waste and / or to make the beverage tablets compostable after use.

[0026] A beverage tablet may be used to form a beverage such as tea, coffee, espresso, cocoa or other beverages prepared from a powder, dry concentrate or dry beverage material such as suitably prepared coffee beans, tea leaves etc. The beverage machine may form such beverages using a base liquid, such as water, that may be combined with the beverage material under suitable conditions to form the beverage.

[0027] In some embodiments, a beverage tablet may have a body and an outer wall, where the body and / or the outer wall are made of one or more beverage ingredients. Examples of beverage ingredients include, but are not limited to: coffee (e.g., coffee grounds, soluble coffee), tea (e.g. tea leaves, dry herbal tea), powdered beverage concentrate, dried fruit extract or powder, powdered or liquid concentrated bouillon or other soup, powdered or liquid medicinal materials (e.g. nutraceuticals), powdered milk or other creamers, sweeteners, thickeners, flavorings, binding agents, coating agents, cellulose, chaff, filter aids, extracts, plant husks, plant fibers, bagasse, additives, or any other type of food. Examples of filter aids include, but are not limited to, perlite, diatomaceous earth, diatomite, chaff, and cellulose. Examples of binding agents include, but are not limited to, cellulose, cellulose derivatives, gelatin, cream, honey, starch, sucrose, mannitol, liquid glucose, and zein.

[0028] In one aspect, beverage tablets comprising coatings are provided. Beverage tablet coatings may provide any of a number of advantages for use in beverage tablets. For example, in some embodiments, a coating helps to keep one or more beverage ingredients of the beverage tablet fresh (e.g., by helping to limit the amount of oxygen or water to which one or more beverage ingredients of the beverage tablet are exposed), to mechanically support the beverage ingredient, to mark or label the beverage ingredient, or to retain the beverage ingredient within the beverage tablet (e.g. the coating may be configured to retain a residual beverage ingredient formed during brewing). The coating of the beverage tablet may be configured to permit wetting and / or dissolution of beverage ingredients of a beverage tablet. Generally, the coating at least partially surrounds the beverage tablet. The coating is configured to become malleable when wet, allowing for deforming of the beverage tablet by surfaces of a brew chamber. In some embodiments, the coating is configured to stretch as the beverage tablet is deformed, preventing fractures or tears in the coating. The coating is configured to be pierced by at least one inlet needle and one outlet needle. In some embodiments, the coating may not permit transmission of water through the coating, preventing water from flowing in or out of the beverage tablet at locations other than locations where the beverage tablet is pierced.

[0029] In some embodiments, a beverage tablet having a generally cylindrical intermediate region, a first end comprising a first domed region and a second end comprising a second domed region is provided. Such geometry may allow for more even distribution of the coating over the entire surface of the tablet. It may also reduce likelihood of breakage during manufacture or transport due to its avoidance of sharp edges leading to stress concentrations. Such geometry may also allow for even deformation of the beverage tablet in the brew chamber. Additionally, such geometry may greatly reduce the complexity and cost of a beverage machine configured to brew different sized beverage tablets. Such beverage tablets may be scaled along a single dimension by simply altering the height of the cylindrical intermediate region of thebeverage tablet between the two domed regions. A brew chamber of the beverage machine could therefore accommodate various sized beverage tablets while maintaining proper geometry by simply scaling along that single dimension. Additionally, manufacturing such beverage tablets could only require the use of a single sized die, potentially reducing cost and increasing the flexibility of manufacturing lines.

[0030] In some embodiments, the first and second domed regions may be generally curved. In some embodiments, the first and second domed regions may include flat surfaces at distal ends of the first and second domed regions. In some embodiments, the beverage tablet includes the first domed region, but not the second domed region.

[0031] In some embodiments, the beverage tablet includes rounded transition regions between the generally cylindrical intermediate region and the domed regions of the first and second ends. Such rounded transitions may further improve the homogeneity of the coating and reduce stress concentrations. Such rounded transition regions may also allow for better deformation of the beverage tablet in the brew chamber.

[0032] In some embodiments, a method of brewing a brewed beverage using the beverage tablet is provided. In use, a beverage tablet is inserted into a brew chamber of a brewing machine, such that the first and second ends each face one of an inlet surface or outlet surface of the brew chamber. The coating is then wet with a precursor volume of water, allowing the coating to become malleable. The inlet surface is then configured to move towards the outlet surface, compressing the beverage tablet between the inlet surface and the outlet surface. In some embodiments, the shape of the first and / or second ends may change when the beverage tablet is compressed. As an example, the dome shape of the first and / or second ends may transition into a flat surface.

[0033] As the beverage tablet is compressed, the tablet may be deformed to conform to the shape of at least the inlet surface. This may help to seal the beverage tablet against the inlet surface, preventing a flow of water from circumventing the beverage tablet. In some embodiments, because the coating is malleable, the coating stretches with the beverage tablet as the tablet is deformed, rather than fracturing. However, in other embodiments, as the beverage tablet is deformed, the compressed beverage ingredient inside the coating is fractured.

[0034] The beverage tablet is then pierced through one of the first and second ends by at least one inlet needle. In some embodiments, the at least one inlet needle extends from the inlet surface. In some embodiments, the beverage tablet may be pierced through the other of the first and second ends by at least one outlet needle. In some embodiments, the at least one outlet needle extends from the outlet surface. It is contemplated that the at least one outlet needle may pierce the beverage tablet at the same time as, or before, the at least one inlet needle pierces the beverage tablet, or may pierce the beverage tablet at any point of the brewing process.

[0035] A first volume of water is then introduced into the beverage tablet from the inlet needle. Because the beverage tablet is sealed against the inlet surface, this volume of water is not discouraged from circumventing the beverage tablet, and rather must enter the beverage tablet. In some embodiments, this first volume of water causes the beverage tablet to expand and loosens the compacted beverage ingredient up, lowering the density of the beverage ingredient in the beverage tablet.

[0036] A second volume of water is then injected into the beverage tablet through the inlet needle which flows through the beverage tablet and through the outlet needle to a dispensing station, forming a brewed beverage.

[0037] Turning to the figures, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described relative to these embodiments may be used either individually and / or in any desired combination as the disclosure is not limited to only the specific embodiments described herein.

[0038] FIGs. 1A and IB show a perspective and side view respectively of a beverage tablet 100 according to an embodiment. Beverage tablet may include body 102, which includes one or more beverage ingredients formed into a solid body by compression, adhesion, solidification in a mold, or any of a variety of other suitable methods for making a rigid body from one or more beverage ingredients. Compressed beverage ingredient may be any beverage ingredient or combination of beverage ingredients for forming a brewed beverage. For example, beverage ingredient may be coffee grinds, tea leaves, a combination of coffee grinds or tea leaves and additives such as powdered creamer, or any other conventional brewed beverage ingredient.

[0039] Beverage tablet 100 may be at least partially covered by at least one coating 104. Coating 104 may be configured to help retain body 102 in its shape after being formed. Coating 104 may also be configured to seal the beverage ingredient in body 102 to preserve the beverage ingredient by limiting the amount of water or air a beverage ingredient is exposed to. Coating 104 may also be configured to be malleable when wet, in order to allow for deforming of the beverage tablet 100 during a brew process without fracturing or tearing the coating 104. Coating 104 may be configured to be pierced by needles to allow introduction of water into the beverage tablet 100, and extraction of brewed beverage from the beverage tablet. In some embodiments, the coating 104 may be water impermeable, such that water is prevented from flowing in or out of the beverage tablet at locations other than locations where the beverage tablet 100 is pierced.

[0040] In some embodiments, coating 104 may be marked with indicia 116 to indicate information about the beverage ingredients which the beverage tablet 100 includes. In some embodiments, indicia 116 is machine readable, and may be read by beverage machine 200 in order to set brew parameters. In some embodiments, indica 116 is a barcode, including, but notlimited to: one-dimensional barcodes (also called linear barcodes), two-dimensional barcodes (also called matrix codes, e.g. QR codes), and any other suitable barcode. Indicia 116 may be formed on coating 104 using any suitable techniques, such as stamping or laser etching. In some embodiments, indicia comprises a compostable sticker attached to coating 104.

[0041] In some embodiments, it may be desirable for body 102 to have generally curved surfaces. In some embodiments, the curved surfaces may enable the tablet to be more easily deformed by a beverage machine during a brew process. Such deformation may help the tablet to form a seal against a brew chamber of the beverage machine to facilitate beverage formation. In some embodiments, the curved surfaces may allow the tablet to more closely fit with the shape of a brew chamber, which may also have curved walls. In some embodiments, the curved surfaces of the beverage tablet may also help reduce stress concentrations in body 102 and reduce undesirable breaking or chipping of body 102.

[0042] Body 102 may therefore have domed regions at first end 106 and second end 108 to help promote beverage formation with an associated beverage machine and reduce stress concentrations. Such domed regions may also improve brew operation by providing alignment characteristics, as will be explained below. On the other hand, the inventors have also recognized that providing domed regions with radius of curvatures that are too small may result in uneven coatings. As such, the inventors have identified a range of radius of curvatures for use in some embodiments.

[0043] In some embodiments, the radius of curvature R1 of the domed regions ranges from 50 to 80 mm, 52 to 78 mm, 54 to 76 mm, 55 to 75 mm, 56 to 74 mm, 58 to 72 mm, or 69 to 71 mm when body 102 is uncoated. In some embodiments, the radius of curvature R1 of the domed regions is 70 mm when body 102 is uncoated.

[0044] In some embodiments, adding coating 104 may alter radius of curvature R1 when the beverage tablet 100 is uncoated. In some embodiments, the radius of curvature R1 of the domed regions ranges from 80 mm to 30 mm, 75 mm to 35 mm, 70 mm to 40 mm, 65 mm to 45 mm, 60 mm to 50 mm, or 52 mm to 57 mm, when the body 102 is coated with coating 104. In some embodiments, the radius of curvature R1 of the domed regions ranges from 20 mm to 60 mm, 25 mm to 55 mm, 30 mm to 50 mm, 35 mm to 45 mm, or 37 mm to 43 mm, when body 102 is coated. In some embodiments, the radius of curvature R1 of the domed regions ranges from 90 mm to 40 mm, 85 mm to 45 mm, 80 mm to 50 mm, 75 mm to 55 mm, 70 mm to 60 mm, or 63 mm to 68 mm, when the body 102 is coated 104.

[0045] The inventors found that too small of a radius of curvature R1 can result in uneven coatings, while too large of a radius of curvature could result in a shape that is too flat to provide the benefits of a rounded shape. Furthermore, for the same coating homogeneity and stress concentration reduction reasons described above, it may be desirable for the intermediateregion 110 between first and second ends 106 and 108 to be generally cylindrical. This combination of a cylindrical intermediate region 110 bordered by domed first and second ends 106 and 108 may also improve ease of scalability of the beverage tablet 100 while retaining the coating evenness and stress concentration reduction benefits.

[0046] For instance, it may be desirable for the beverage tablet 100 to be available in multiple sizes to allow users to brew different sized beverages with a single brewing machine. Different tablet sizes may be produced, where a height H (see FIG. 2A-2B) of the tablet may differ between the different tablet sizes to achieve a desired volume of beverage ingredient, while the diameter D may remain the same across the different tablet sizes. Providing different tablet sizes having the same diameter may also allow for a brew chamber to be configured to hold multiple different sized beverage tablets 100 without requiring scaling of the brew chamber in multiple dimensions. Providing different tablet sizes having the same diameter may also allow for multiple different sized beverage tablets 100 to be produced using a single die, form, or mold.

[0047] In some embodiments, the diameter D is at least 20 mm, 22, mm, 24 mm, 26 mm, 28 mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm, 35 mm, 36 mm, 37 mm, 38 mm, 39 mm, or 40 mm. In some embodiments, the maximum diameter D2 is less than 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, 55 mm, 50 mm, 49 mm, 48 mm, 47 mm, 46 mm, 45 mm, 44 mm, 43 mm, 42 mm, 41 mm, 40 mm, 39 mm, 38 mm, 37 mm, 36 mm, 35 mm, 34 mm, 33 mm, 33 mm, 32 mm, 31 mm, 30 mm, 25 mm or 20 mm. It should be appreciated that ranges of the aforementioned diameters are possible as well. For example, in some embodiments, the diameter D is 20 to 100 mm, 20 to 90 mm, 20 to 80 mm, 20 to 70 mm, 22 to 60 mm, 24 to 50 mm, 25 to 45 mm, 25 to 45 mm, 30 to 45, 30 to 45 mm, 30 to 35 mm, or 35 to 45 mm.

[0048] In some embodiments, the ratio of the diameter of the beverage tablet to the overall height of the tablet is greater than 1, such that the diameter is larger than the height. In some embodiments, the ratio of the diameter of the beverage tablet 100 to the overall height of the beverage tablet ranges from 7:6.5 to 7:2, 7:6 to 7:2, 7:5.5 to 7:2, 7:5 to 7:2, 7:4.5 to 7:2, 7:4 to 7:2, 7:3.5 to 7:2, 7:3 to 7:2, and 7:2.5 to 7.2. In some embodiments, the ratio of the diameter of the beverage tablet 100 to the overall height of the beverage tablet ranges from 7:6.5 to 7:2, 7:6.5 to 7:2.5, 7:6.5 to 7:3, 7:6.5 to 7:3.5, 7:6.5 to 7:4, 7:6.5 to 7:4.5, 7:6.5 to 7:5, 7:6.5 to 7:5.5, and 7:6.5 to 7:6. In some embodiments, the ratio of the diameter of the beverage tablet 100 to the overall height of the beverage tablet ranges from 1.1 to 1.3, 1.2 to 1.6, 1.5 to 1.8, 3 to 4, 3.3 to 3.7. In some embodiments, the ratio of diameter of the beverage tablet 100 to the overall height of the beverage tablet is approximately any of the following ratios: 7:8, 7:6.5, 7:6, 7:5.5, 7:5, 7:4.5, 7:4, 7:3.5, 7:3, 7:2.5, or 7:2.

[0049] In other embodiments, however, the ratio of the diameter of the beverage tablet to the overall height of the tablet is less than 1, such that the diameter is smaller than the height. In some embodiments, the ratio of the diameter of the beverage tablet 100 to the overall height of the beverage tablet ranges from 0.7 to 0.95, 0.75 to 0.95, 0.8 to 0.95, 0.85 to 0.95, 0.9 to 0.95, 0.7 to 0.75, 0.7 to 0.8, 0.7 to 0.85, 0.7 to 0.9, 0.7 to 0.9, or 0.8 to 0.9.

[0050] In yet other embodiments, the ratio of the diameter of the beverage tablet to the overall height of the tablet is 1, such that the diameter and height are the same.

[0051] In some embodiments, the ratio of diameter of the beverage tablet 100 to the overall height of the beverage tablet may be any ratio between 7:10 and 7:2.

[0052] In some embodiments, to further improve coating evenness and reduction of stress concentrations, transitions 112 and 114 between the intermediate region 110 and the domed regions of the first and second ends 106 and 108 may be generally curved. It is contemplated that this curve may have any suitable radius. In some embodiments, transitions 112 and 114 are more gradual (larger radius of curvature R2), as can be seen in FIG. 3A. In other embodiments, transitions 112 and 114 are sharper (smaller radius of curvature R2), as can be seen in FIG. 3B.

[0053] In some embodiments, as seen in Fig. 3C, domed regions of the first and second ends 106 and 108 may include flat surfaces 118 and 120.

[0054] The inventors have recognized that a radius of curvature R2 that is too small (a sharper corner) could result in a less even coating, and may give rise to manufacturing issues (e.g. the tablet may have difficulty being ejected from a die if the corner is too sharp). On the other hand, the inventors have also recognized that a radius of curvature R2 that is too large may make the tablet less compact, and / or may distort the general cylindrical shape of the tablet.

[0055] As such, according to one aspect, the inventors have identified a range of radius of curvatures for use in some embodiments. In some embodiments, the radius of curvature R2 of the transition ranges from 1.5 mm to 2.5 mm, 1.6 mm to 2.4 mm, 1.7 mm to 2.3 mm, 1.8 mm to 2.2 mm, 1.9 mm to 2.1 mm, 1.95 mm to 2.05 mm, or 1.98 mm to 2.02 mm when the beverage tablet 100 is uncoated. In some embodiments, the radius of curvature of the transition is 2 mm when the beverage tablet is uncoated.

[0056] In some embodiments, adding coating 104 to beverage tablet 100 may alter the radius of curvature R2. In some embodiments, the radius of curvature R2 of the transition ranges from 3 mm to 10 mm, 4 mm to 9 mm, 5 mm to 8 mm, or 6 mm to 7 mm when the beverage tablet 100 is coated with coating 104. In some embodiments, the radius of curvature R2 of the transition ranges from 6 mm to 12 mm, 7 mm to 11 mm, 8 mm to 10 mm or 8.5 mm to 9.5 mm, when the beverage tablet 100 is coated with coating 104. In some embodiments, the radius of curvature R2 of the transition ranges from 2 mm to 8 mm, 3 mm to 7 mm, 4 mm to 6 mm, or 4.1mm to 4.8 mm, when the beverage tablet 100 is coated with coating 104. In some embodiments, the radius of curvature R2 of the transition ranges from 5 mm to 5.8 mm or 5.2 mm to 5.6 mm, when the beverage tablet 100 is coated with coating 104.

[0057] FIGs. 4-6 show an exemplary embodiment of a method of brewing a beverage using the beverage tablet.

[0058] In use, a beverage tablet 100 may be received into a brew chamber 202 of a beverage machine 200 while the brew chamber 202 is in an expanded configuration, as shown in FIG. 4. Brew chamber 202 includes an inlet surface 204 and an outlet surface 206. An inlet needle 210 may be coupled to the inlet surface 204, and an outlet needle 212 may be coupled to the outlet surface 206. It is contemplated that inlet needle 210 may be a plurality of inlet needles, and / or outlet needle 212 may be a plurality of outlet needles. In some embodiments, inlet surface 204 may have a curved profile. In some embodiments, outlet surface 206 may have a curved profile.

[0059] Beverage tablet 100 may be inserted such that first and second ends 106 and 108 each face one of an inlet surface 204 or an outlet surface 206.

[0060] In some embodiments, the brew chamber 202 may include a lid 208 that opens to permit entry of a tablet into the brew chamber. The lid 208 may close after a tablet has been inserted.

[0061] As a wetting step, a precursor volume of water may be introduced into the brew chamber in order to soften coating 104 to allow for deforming and piercing of the beverage tablet 100. In some embodiments, the precursor volume of water in introduced into the brew chamber through inlet needle 210. In some embodiments, precursor volume of water is introduced into the brew chamber from a separate inlet that is distinct from inlet needle 210.

[0062] In some embodiments, after the tablet coating has been softened, the beverage machine may then compress the tablet. To achieve this, in some embodiments, the inlet surface 204 and outlet surface 206 may move relative to one another, moving the brew chamber 202 from an expanded configuration (FIG. 4) to a compressed configuration (FIG. 5). In some embodiments, the inlet surface 204 moves toward the outlet surface 206, in some embodiments, the outlet surface 206 moves toward the inlet surface 204, and in some embodiments, both surfaces 204, 206 move toward each other. In some embodiments, as the beverage tablet 100 is compressed, the first and / or second ends 106 and 108 may change shape. For example, the first and / or second ends 106 and 108 may change from a domed shape to a flattened shape.

[0063] The movement distance of the inlet surface 204 and / or outlet surface 206 may differ depending on the size of the beverage tablet. For example, the inlet surface 204 and / or outlet surface may move a greater distance when used with tablets of a shorter height H (e.g., the tablet shown in FIG. 2A) as compared to tablets with a taller height H (e.g. the tablets shown inFIGS. 2B and 2C). As discussed above, one benefit of using a cylindrical shaped beverage tablet is that different beverage tablet sizes (and thus beverage volumes and / or strengths) may be used with a beverage machine, where the beverage machine may be able to adjust along a single dimension to accommodate the different sizes. In this case, the brew chamber expands and contracts linearly to accommodate different beverage tablet heights.

[0064] In some embodiments, as the distance between the inlet surface 204 and the outlet surface 206 decreases, the beverage tablet 100 is deformed such that the tablet conforms to match the shape of the inlet surface 204 and / or outlet surface 206 in the compressed position. In some embodiments, the conforming of the beverage tablet 100 to inlet surface 204 seals the beverage tablet 100 against inlet surface 204. In some embodiments, conforming of the beverage tablet 100 to the outlet surface 206 seals the beverage tablet 100 against the outlet surface 206.

[0065] In some embodiments, the beverage tablet is subjected to a force during compression of the tablet by the beverage machine. In some embodiments, the force the beverage tablet is subjected to ranges from 400 N to 750 N, 425 N to 725N, 450 N to 700 N, 475 N to 675 N, 500 N to 650 N, 525 N to 625 N, or 550 N to 600 N. In some embodiments, the force the beverage tablet is subjected to ranges from 300 N to 550 N, 325 N to 525 N, 350 N to 500 N, or 375 N to 475 N. In some embodiments, the force the beverage tablet is subjected to ranges from 600 N to 800 N, 625 N to 775 N, 650 N to 750 N, or 675 N to 725 N.

[0066] In some embodiments, compressing the beverage tablet 100 causes the compacted beverage ingredients forming the body 102 to fracture, breaking body 102 into smaller pieces. The coating 104 may remain intact and may hold the fractured pieces of the body within an encapsulated space to prevent the beverage ingredients from dispersing. The coating may stretch to permit the shape of the tablet to deform without rupture of the coating.

[0067] In some embodiments, the shape of the beverage tablet may provide an alignment effect within the brew chamber. In some embodiments, when beverage tablet is placed inside the brew chamber 202, a center of the beverage tablet CBT (see FIG. 4) will not be aligned with a center of the brew chamber CBC(OT some other intended alignment position of the tablet - in some embodiments, the tablet may not be intended to align to a center of the brew chamber). As the distance between the inlet surface 204 and the outlet surface 206 decreases, contact between the domed regions of the first and second ends 106 and 108 and the curved profiles of inlet surface 204 and outlet surface 206 pushes the center of the beverage tablet CBT towards the center of the brew chamber CBC. In this manner, beverage tablet 100 may be approximately centered with both inlet surface and outlet surface prior to deformation, which may result in more even deformation across the inlet and outlet surfaces 204 and 206 when beverage tablet 100 is deformed. Alternatively or in addition, this may help to align the tablet relative to the inletand / or outlet needles 210, 212, which may allow water to be introduced into the tablet at a desired position, which may help to increase extraction yields during beverage formation.

[0068] As the beverage tablet 100 is compressed, the inlet needle 210 pierces coating 104 and enters the beverage tablet 100 through the first end 106. In some embodiments, the outlet needle 212 may also pierce coating 104 and enter the beverage tablet 100 through the second end 108 contemporaneously with the inlet needle. In other embodiments, the outlet needle 212 pierces coating 104 after the inlet needle 210 pierces the coating 104.

[0069] A first volume of water is then injected into the beverage tablet 100 through the inlet needle 210. In some embodiments, this causes beverage tablet 100 to expand, as seen in FIG. 6. In some embodiments, as beverage tablet 100 expands, the surfaces of the brew chamber may move away from one another to allow for expansion. For example, the inlet surface 204 of the brew chamber may move away from the outlet surface 206 of the brew chamber (or vice versa, or both surfaces may move away from each other). As beverage tablet 100 expands, the contents of the body 102 may become broken up, reducing the density of the beverage ingredient in the beverage tablet 100. The coating 104, however, may remain intact, keeping the contents contained within an enclosed space and preventing the contents from dispersing in the beverage machine. The coating may stretch to permit the shape of the tablet to deform and the density of the body to change without rupture of the coating.

[0070] In some embodiments, the coating may be configured to permit the tablet to expand inside the brew chamber without rupture of the coating. In some embodiments, the permitted range of expansion inside the brew chamber is from 10%-27%, 11% to 26%, 12% to 25%, 13% to 24%, 14% to 23%, 15% to 22%, 16% to 21%, 17% to 20%, or 18% to 19%. In some embodiments, the permitted range of expansion inside the brew chamber is from 10%- 20%, 11% to 19%, 12% to 18%, 13% to 17%, 14% to 16%, or 15%. In some embodiments, the permitted range of expansion inside the brew chamber is from 14% to 30%, 15% to 29%, 16% to 28%, 17% to 27%, 18% to 26%, 19% to 25%, 20% to 24%, 21% to 23%, or 22%. In some embodiments, the permitted range of expansion inside the brew chamber is from 15%-30%.

[0071] In some embodiments, a second volume of water may then be introduced into the beverage tablet 100 through inlet needle 210. At least some of the first and second volumes of water then flow through the beverage tablet 100, out the outlet needle 212, and to a dispensing station, forming a brewed beverage.

[0072] In some embodiments, prior to operation with a beverage machine, a beverage tablet may have a density of 500 g / 1 to 750 g / 1. In some embodiments, the beverage tablet may have a density that ranges from 400 g / 1 to 850 g / 1, 425 g / 1 to 825 g / 1, 450 g / 1 to 800 g / 1, 475 g / 1 to 775 g / 1, 500 g / 1 to 750 g / 1, 525 g / 1 to 725 g / 1, 550 g / 1 to 700 g / 1, 575 g / 1 to 675 g / 1, or 600 g / 1 to 650 g / 1. In some embodiments, the beverage tablet may have a density that ranges from 400 g / 1to 600 g / 1, 425 g / 1 to 575 g / 1, 450 g / 1 to 550 g / 1, 475 g / 1 to 525 g / 1, or 500 g / 1. In some embodiments, the beverage tablet may have a density that ranges from 650 g / 1 to 850 g / 1, 675 g / 1 to 825 g / 1, 700 g / 1 to 800 g / 1, 725 g / 1 to 775 g / 1, or 750 g / 1.

[0073] As discussed above, in some embodiments, the beverage tablet may comprise at least one coating that at least partially covers the compacted beverage ingredient. In some embodiments, the at least one coating completely envelops the compacted beverage ingredient. The coating may be configured to be malleable when exposed to liquid to allow the beverage tablet to deform during a beverage formation process without rupture of the coating. In some embodiments, the coating has an ultimate elongation of at least 10% when exposed to liquid. In some embodiments the coating has an ultimate elongation that ranges from 10% to 40%, 12% to 38%, 14% to 36%, 16% to 34%, 18% to 32%, 20% to 30%, 22% to 28%, or 24% to 26%. In some embodiments the coating has an ultimate elongation that ranges from 10% to 28%, 12% to 26%, 14% to 24%, 16% to 22%, or 18% to 20%. In some embodiments the coating has an ultimate elongation that ranges from 24% to 40%, 26% to 38%, 28% to 36%, 30% to 34%, or 31% to 33%.

[0074] In some embodiments, the coating has an ultimate tensile strength of 100 psi to 280 psi when exposed to liquid. In some embodiments, the ultimate tensile strength of the coating ranges from 100 psi to 280 psi, 120 psi to 260 psi, 140 psi to 220 psi, or 160 psi to 200 psi when exposed to liquid. In some embodiments, the ultimate tensile strength of the coating ranges from 90 psi to 150 psi, 100 psi to 140 psi, or 110 psi to 130 psi when exposed to liquid. In some embodiments, the ultimate tensile strength of the coating ranges from 230 psi to 290 psi, 240 psi to 280 psi, or 250 psi to 270 psi when exposed to liquid. In some embodiments, the coating comprises a polysaccharide, such as sodium alginate.

[0075] In some embodiments, the beverage tablet with coating may have a break force, which is the force necessary to fracture the beverage tablet when the beverage tablet is compressed along beverage tablet sides 122 (See FIG IB). In some embodiments, the break force ranges from 10 N to 260 N, 20 N to 250 N, 30 N to 240 N, 40 N to 230 N, 50 N to 220 N, 60 N to 210 N, 70 N to 200 N, 80 N to 190 N, 90 N to 180 N, 100 N to 170 N, 110 N to 160 N, 120 N to 150 N, or 130 N to 140 N. In some embodiments, the break force ranges from 5 N to 130 N, 10 N to 120N, 20 N to 110 N, 30 N to 100 N, 40 N to 90 N, 50 N to 80 N, or 60 N to 70 N. In some embodiments, the break force ranges from 5 N to 35 N, 10 N to 30 N, or 15 N to 25 N. In some embodiments, the break force ranges from 130 N to 260 N, 140 N to 250 N, 150 N to 240 N, 160 N to 230 N, 170 N to 220 N, 180 N to 210 N, or 190 N to 200 N. In some embodiments, the break force ranges from 240 N to 270 N, 245 N to 265 N, or 250 N to 260 N.

[0076] FIG. 7 shows a body of a beverage tablet being formed in a die assembly. In some embodiments, body 102 may be formed by compression in a die assembly. Loosebeverage ingredient may be placed inside of die assembly 300 such that the loose beverage ingredient is surrounded by first die section 302, second die section 304, and die sidewalls 306. Sidewalls 306 may be a generally cylindrical tube, with first and second die section disposed inside of the generally cylindrical tube. First die section 302 and / or second die section 304 may then compress the loose beverage ingredient into body 102. In some embodiments, one of the first or second die sections moves towards the other section to compress the loose beverage material. In some embodiments, the first and second die sections move towards each other to compress the beverage material. In some embodiments, first die section 302 and / or second die section 304 may include concave sections with a radius of curvature R3, which forms radius of curvature R1 (see FIG. IB) of the beverage tablet during compression of body 102. Alternatively, or in addition, first die section 302 and / or second die section 304 may include concave sections with a radius of curvature R4, which forms radius of curvature R2 (see FIG. IB) of the beverage tablet during compression of the body 102.

[0077] In some embodiments, the radius of curvature R3 ranges from 45 mm to 80 mm, 52 mm to 78 mm, 54 mm to 76 mm, 55 mm to 75 mm, 50 to 80 mm, 50 to 60 mm, 60 to 70 mm, 70 to 80 mm, 45 to 55 mm, 55 to 65 mm, 65 to 75 mm, 56 mm to 74 mm, 58 mm to 72 mm, 69 mm to 71 mm, 60 to 64 mm, 64 to 68 mm, 68 to 72 mm, 72 to 76 mm, 76 to 80 mm, 80 to 84 mm, 80 to 82 mm, 82 to 84 mm, 84 to 86 mm, 86 to 88 mm, 88 to 90 mm, 88 to 82 mm, 20 to 50 mm, 22 to 48 mm, 24 to 46 mm, 26 to 44 mm, 28 to 42 mm, 30 to 40 mm, 32 to 38 mm, or 34 to 36 mm. In some embodiments, the radius of curvature R3 is 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 50, 55, 60, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, or 75 mm. In some embodiments, the radius of curvature R4 ranges from 1 mm to 2.5 mm, 1.6 mm to 2.4 mm, 1.7 mm to 2.3 mm, 1.8 mm to 2.2 mm, 1.9 mm to 2.1 mm, 1.95 mm to 2.05 mm, 1.98 mm to 2.02 mm, 1 to 2 mm, 1.2 to 1.8 mm, 1.4 to 1.6 mm, 1.45 mm to 1.55 mm, or 0.5 mm to 1.5 mm, 0.6 mm to 1.4 mm, 0.7 mm to 1.3 mm, 0.8 mm to 1.2 mm, 0.9 mm to 1.1 mm, or 0.95 mm to 1.05 mm. In some embodiments, the radius of curvature R4 is 0.5, 0.6, 0.7, 0.8, 0.85, 0.9, 0.95, 1, 1.05, 1.1, 1.15, 1.2, 1.25, 1.3, 1.35, 1.4, 1.45, 1.5, 1.55, 1.6, 1.65, 1.7, 1.75, 1.8, 1.85, 1.9, 1.95, 2, 2.05, 2.1, 2.15, 2.2, 2.25, 2.3, 2.35, 2.4. 2.35, or 2.5 mm. In some embodiments, the radius of curvature R3 may be smaller than the desired radius of curvature R1 to allow for expansion of body 102 after the beverage tablet is released from the die 300. In some embodiments, the radius of curvature R4 may be smaller than the desired radius of curvature R2 to allow for expansion of body 102 after the beverage tablet is released from the die 300.

[0078] In some embodiments, the sidewalls 306 form a cylindrical section of the die assembly that may form the cylindrical intermediate region of the beverage tablet between the first and second ends. As seen in FIG. 7, the cylindrical section of the die assembly may have a maximum internal diameter Dd. In some embodiments, the maximum diameter Dd is at least 20mm, 22, mm, 24 mm, 26 mm, 28 mm, 30 mm, 31 mm, 32 mm, 33 mm, 34 mm or 35 mm. In some embodiments, the maximum diameter Dd is less than 100 mm, 90 mm, 80 mm, 70 mm, 60 mm, 55 mm, 50 mm, 49 mm, 48 mm, 47 mm, 46 mm, 45 mm, 44 mm, 43 mm, 42 mm, 41 mm, 40 mm, 39 mm, 38 mm, 37 mm, 36 mm, 35 mm, 34 mm, 33 mm, 33 mm, 32 mm, 31 mm, 30 mm, 25 mm or 20 mm. It should be appreciated that ranges of the aforementioned diameters are possible as well. For example, in some embodiments, the maximum diameter Dd is 20 to 100 mm, 20 to 90 mm, 20 to 80 mm, 20 to 70 mm, 22 to 60 mm, 24 to 50 mm, 25 to 45 mm, 25 to 45 mm, 30 to 45, 30 to 45 mm, 30 to 35 mm, or 35 to 45 mm.

[0079] While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art. Accordingly, the foregoing description and drawings are by way of example only.

Claims

CLAIMSWhat is claimed is:

1. A beverage tablet for use with a beverage machine to form a beverage, the beverage tablet comprising: a body comprising a first end, a second end, and a cylindrical intermediate region between first and second ends, the first end comprising a domed region, and wherein the body further comprises beverage ingredient compacted into a first density; and at least one coating at least partially covering the compacted beverage ingredient, wherein the at least one coating is configured to be malleable when exposed to liquid to allow for the domed region to be deformed by application of force from a beverage machine in order to conform to a shape of a brew chamber of the beverage machine and form a seal against the brew chamber; and wherein the body and the at least one coating are configured to be pierced to allow liquid to flow into the beverage tablet and the at least one coating is configured to be malleable when exposed to liquid to allow for the beverage tablet to be expanded by the liquid to lower the first density of the beverage ingredient to a second density.

2. The beverage tablet of claim 1, wherein the beverage tablet comprises a diameter and a height, and wherein the ratio of diameter to height is at least 7:8.

3. The beverage tablet of claim 1, wherein the beverage tablet comprises a diameter and a height, and wherein the ratio of diameter to height ranges from 7:6.5 to 7:2.

4. The beverage tablet of claim 1, wherein the beverage tablet comprises a diameter and a height, and wherein the ratio of diameter to height is greater than 1:1.

5. The beverage tablet of claim 1, wherein the beverage tablet comprises a diameter and a height, and wherein the ratio of diameter to height is less than 1:1.

6. The beverage tablet of claim 1, further comprising machine readable indica at the domed region.

7. The beverage tablet of claim 6, wherein the indicia is a barcode.

8. The beverage tablet of claim 7, wherein the barcode is a two-dimensional barcode.

9. The beverage tablet of claim 7, wherein the indicia is laser-etched onto the coating.

10. The beverage tablet of claim 1, wherein the coating is configured to stretch and remain intact when the tablet is subjected to a compression force of 400 to 750 N by a beverage machine.

11. The beverage tablet of claim 1, wherein the beverage tablet has a density of 500 to 750 g / 1-12. The beverage tablet of claim 1, wherein the coating is configured to permit the beverage tablet to expand by 15-30% inside the brew chamber without rupture of the coating when the coating is exposed to liquid.

13. The beverage tablet of claim 1, wherein the domed region is a first domed region, and wherein the second end comprises a second domed region.

14. The beverage tablet of claim 1, wherein the body further comprises a first rounded transition between the first domed region and the cylindrical intermediate region, and a second rounded transition between the cylindrical intermediate region and the second domed region.

15. The beverage tablet of claim 14, wherein the first domed region has a radius of curvature of 55 to 75 mm.

16. The beverage tablet of claim 14, wherein the first rounded transition has a radius of curvature of 1.8 to 2.2 mm.

17. The beverage tablet of claim 1, wherein the domed region comprises a generally curved surface.

18. The beverage tablet of claim 1, wherein the domed region includes a flat surface.

19. A method of forming a beverage using a beverage tablet, wherein the beverage tablet comprises a body with a first end comprising a domed region, a second end, a cylindrical intermediate region between the first end and second end, and a coating around at least a portion of the body, the method comprising:receiving the beverage tablet into a brew chamber of a beverage machine; introducing water into the brew chamber to wet the beverage tablet and soften the coating; applying a force to the beverage tablet, causing the beverage tablet to deform and conform to a shape of the brew chamber; piercing the first end with at least one inlet needle; introducing a volume of water into the beverage tablet through the at least one inlet needle; and allowing brewed beverage to exit the brew chamber.

20. The method of claim 19, wherein the volume of water is a first volume of water, and wherein introducing the first volume of water through the at least one inlet needle and into the beverage tablet causes the beverage tablet to expand and lowers a density of a beverage ingredient of the tablet.

21. The method of claim 20, further comprising introducing a second volume of through the at least one inlet needle and into the beverage tablet, the second volume of water being larger than the first volume of water.

22. The method of claim 19, wherein applying a force to the beverage tablet seals an outer surface of the tablet against at least one surface of the brew chamber.

23. The method of claim 22, wherein the at least one surface of the brew chamber is a surface adjacent to the at least one inlet needle.

24. The method of claim 19, further comprising piercing the second end with at least one outlet needle.

25. The method of claim 24, wherein brewed beverage exits the beverage tablet through the at least one outlet needle.

26. The beverage tablet of claim 19, wherein the coating is configured to stretch and remain intact when the tablet is subjected to a compression force of 400 to 750 N by a beverage machine.

27. The beverage tablet of claim 19, wherein the beverage tablet has a density of 500 to 750 g / 1-28. The beverage tablet of claim 19, wherein the coating is configured to permit the beverage tablet to expand by 15 to 30% inside the brew chamber without rupture of the coating when the coating is exposed to liquid.

29. The beverage tablet of claim 1, wherein the coating has an ultimate elongation of at least 18% when exposed to liquid.

30. The beverage tablet of claim 19, wherein the coating has an ultimate elongation of at least 18% when exposed to liquid.

31. A die assembly for compacting beverage ingredient into a body of a beverage tablet, the beverage tablet being for use with a beverage machine to form a beverage, the die assembly comprising: a first die section configured to form a first end of the body; and a second die section configured to form a second end of the body, wherein the first die section comprises a concave section configured to form a domed region of the first end of the body, and wherein the die assembly further comprises a cylindrical section configured to form a cylindrical region of the body between the first and second ends of the body, wherein the cylindrical section has an internal diameter of at least 25 mm.

32. The die assembly of claim 31, wherein the domed region is a first domed region and the concave section is a first concave section, and wherein the second die section comprises a second concave section configured to form a second domed region of the second end of the body.

33. The die assembly of claim 32, wherein the first die section comprises a third concave section configured to form a first rounded transition between the first domed region and a generally cylindrical middle region of the body, and wherein the second die section comprises a fourth concave section configured to form a second rounded transition between the second domed region and the generally cylindrical middle region of the body.

34. The die assembly of claim 31, wherein the cylindrical section is part of at least the first die section or the second die section.

35. The die assembly of claim 31, wherein at least one of the first and second die sections are moveable relative to the cylindrical section.

36. A method of forming a beverage tablet, the beverage tablet being for use with a beverage machine to form a beverage, the method comprising: compressing a beverage ingredient into a body of a beverage tablet using a die assembly, the die assembly having a first die section that forms a first end of the body, a second die section that forms the second end of the body, and a cylindrical section that forms a cylindrical intermediate region of the body between the first and second ends of the body, wherein the first die section comprises a concave section configured to form a domed region of the first end of the body; and coating at least a portion of the beverage tablet with a coating.

37. The method of claim 36, wherein the step of coating the beverage tablet comprises coating the entire beverage tablet with the coating.

38. The method of claim 36, wherein the coating is configured to be malleable when exposed to liquid to allow for the domed region to be deformed by application of force from a beverage machine in order to conform to a shape of a brew chamber of the beverage machine and form a seal against the brew chamber.

39. The method of claim 36, wherein the body and the at least one coating are configured to be pierced to allow liquid to flow into the beverage tablet and the at least one coating is configured to be malleable when exposed to liquid to allow for the beverage tablet to be expanded by the liquid to lower a density of the beverage ingredient.

40. The method of claim 36, wherein the domed region is a first domed region and the concave section is a first concave section, and wherein the second die section comprises a second concave section that forms a second domed region of the second end of the body during the compression step.

41. The method of claim 40, wherein the first die section comprises a third concave section configured to form a first rounded transition between the first domed region and the cylindricalintermediate region of the body, and wherein the second die section comprises a fourth concave section configured to form a second rounded transition between the second domed region and the cylindrical intermediate region of the body.

42. The method of claim 36, wherein the cylindrical section is part of at least the first die section or the second die section.

43. The method of claim 42, wherein at least one of the first and second die sections are moveable relative to the cylindrical section.