Method of manufacturing partially roasted coffee beans and a combination roasting and brewing device

Abstract

Exemplary embodiments disclosed herein provide a method for producing primary roasted coffee beans where green coffee beans are roasted only until the point where the beans have reached the end of the primary roasting phase, where the beans are then quenched to stop the roasting process. In some embodiments, the end of the primary roasting phase is marked by the beans reaching the first crack stage. A disposable package containing primary roasted beans is also disclosed. A device for roasting and brewing ground coffee beans is also disclosed, the device having a porous container which accepts the ground coffee beans; a roasting container which accepts the porous container and has a sidewall containing an aperture; a fan and heating element positioned to force hot air through the aperture; a water containment vessel and heating subassembly positioned above the roasting container; and a water release valve assembly positioned between the water containment vessel and the roasting container.

Claims

1. A package of ground primary roasted coffee beans comprising: a lower filter body having a perimeter; ground primary roasted coffee beans placed in the lower filter body; and an upper filter having a perimeter which is sealed to the perimeter of the lower filter body.

2. The package of claim 1 wherein: the upper filter and lower filter body are metallic.

3. The package of claim 1 wherein: the upper filter is comprised of a material that will not lose its mechanical strength when exposed to air at a temperature of approximately 400 degrees Fahrenheit.

4. The package of claim 1 wherein: the upper filter and lower filter body are ceramic.

5. The package of claim 1 wherein: the ground primary roasted beans have not been fully roasted for consumption.

6. The package of claim 1 further comprising: a rim defined where the perimeter of the lower filter body is sealed to the perimeter of the upper filter body.

7. The package of claim 1 wherein: the ground primary roasted beans have not reached a light roast level.

8. A package of ground primary roasted coffee beans comprising: a lower filter body; ground primary roasted coffee beans which were not permitted to roast past the second crack stage of the roasting process, placed in the lower filter body; and an upper filter attached to the lower filter body.

9. The package of claim 8 wherein: the lower filter body and the upper filter each comprise a metallic screen.

10. The package of claim 8 wherein: a rim defined where the lower filter body is attached to the upper filter body.

11. The package of claim 8 wherein: the lower filter body and the upper filter each have a circular shape.

12. A device for roasting and brewing a package of ground primary roasted coffee beans comprising: a roasting container which accepts the package of ground primary roasted coffee beans and has a sidewall containing an aperture; a fan and heating element positioned to force hot air through the roasting container and contact the ground primary roasted coffee beans; a water containment vessel positioned in fluid communication with the roasting container; and a heating subassembly positioned to heat water contained in the water containment vessel.

13. The device of claim 12 further comprising: a coffee vessel positioned under the package of ground primary roasted coffee beans.

14. The device of claim 13 further comprising: an aroma and brew guide vessel positioned between the package of ground primary roasted coffee beans and the coffee vessel.

15. The device of claim 13 wherein: the flow of hot air creates an area of higher pressure within the roasting container which forces the hot air downward and into the coffee vessel.

16. The device of claim 12 wherein: the roasting container has an interior with a circular rim; and the package of ground primary roasted coffee beans contains a circular lip which rests atop the circular rim.

17. The device of claim 12 wherein: the package of ground primary roasted coffee beans is stratified by the hot air, with a deeper roast in an inner stratum and a lighter roast in an outer stratum.

18. The device of claim 13 wherein: the hot air contacting the ground primary roasted coffee beans is directed into the coffee vessel.

19. The device of claim 12 wherein: the hot air which contacts the ground primary roasted coffee beans causes the beans to re-start the roasting process.

20. The device of claim 12 wherein: the hot air which contacts the ground primary roasted coffee beans causes the beans to become fully roasted and ready for consumption.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A better understanding of an exemplary embodiment will be obtained from a reading of the following detailed description and the accompanying drawings wherein identical reference characters refer to identical parts and in which:

(2) FIG. 1 provides a graphical representation of the Bean Roasting Phases and Aroma Components;

(3) FIG. 2 provides a sectional view of an exemplary embodiment of the device during the finish roasting phase;

(4) FIG. 3: provides a sectional view of an exemplary embodiment of the device during the brewing phase;

(5) FIG. 4A provides a sectional view of an exemplary embodiment of the primary roasted ground coffee package within a roasting container, stratified roasting is illustrated;

(6) FIG. 4B provides a bottom perspective view of an embodiment of a primary roasted ground coffee package.

(7) FIG. 5A provides a sectional view of an exemplary embodiment of the Reusable Roast-Brew Coffee Filter Elements in Brew Vessel, homogeneous roasting is illustrated;

(8) FIG. 5B provides a bottom perspective view of an embodiment of a Reusable Roast-Brew Coffee Filter Element.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

(9) In addition to the features mentioned above, other aspects of the exemplary embodiments of the present invention will be readily apparent from the following descriptions of the drawings and exemplary embodiments, wherein like reference numerals across the several views refer to identical or equivalent features, and wherein: several views refer to identical or equivalent features, and wherein:

(10) The invention is described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. In the drawings, the size and relative sizes of layers and regions may be exaggerated for clarity.

(11) It will be understood that when an element or layer is referred to as being on another element or layer, the element or layer can be directly on another element or layer or intervening elements or layers. In contrast, when an element is referred to as being directly on another element or layer, there are no intervening elements or layers present. Like numbers refer to like elements throughout. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items.

(12) Spatially relative terms, such as lower, upper and the like, may be used herein for ease of description to describe the relationship of one element or feature to another element(s) or feature(s) as illustrated in the figures.

(13) It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation, in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as lower relative to other elements or features would then be oriented upper relative the other elements or features. Thus, the exemplary term lower can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

(14) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

(15) Embodiments of the invention are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of the invention. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments of the invention should not be construed as limited to the particular shapes of regions illustrated herein but are to include deviations in shapes that result, for example, from manufacturing.

(16) For example, an implanted region illustrated as a rectangle will, typically, have rounded or curved features and/or a gradient of implant concentration at its edges rather than a binary change from implanted to non-implanted region. Likewise, a buried region formed by implantation may result in some implantation in the region between the buried region and the surface through which the implantation takes place. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to limit the scope of the invention.

(17) Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

(18) A first embodiment of the invention provides a method of manufacturing partially roasted coffee beans which comprises the steps of roasting green coffee beans to a specific point at the end of the primary roasting phase, preferably completed by quenching the beans (preferably rapidly cooling the beans to ambient or lower temperature).

(19) Please refer to the graph of FIG. 1. The horizontal axis represents a typical roast cycle, graduated in minutes, from start to fully burnt. The vertical axis represents appearance or value of various phenomena, graduated from minimum to maximum. Line 101 represents acidic and vegetal flavors and aroma typical of fresh or partially roasted coffee beans. Line 102 represents caramelization (controlled burning) of internal sugars. Vertical line 103 represents the completion of the Primary Roasting Phase (about 10 minutes) and vertical line 104 represents the completion of the Finish Roasting Phase, shown at the end of a full French Dark Roast (about 14 minutes.) Line 105 represents carbonization burning of the beans' oils and cellulosic material. The primary roasted whole beans may be packaged for delivery to the consumer to finish roast, grind and brew as needed.

(20) Alternatively [in another preferred embodiment] the primary roasted beans may then be ground to a desired size and packaged loose for delivery to the consumer, to be finish roasted as desired and brewed as needed.

(21) Alternatively [in another preferred embodiment] the primary roasted beans may be ground to a desired size prior to finish roasting, then packaged into single-serving or multiple-serving roasting and brewing packages for use in machines designed to finish roasted and then brewed for delivery to the consumer.

(22) The above methods permit on-demand roasting in an expeditious manner for local commercial coffee shops and for home coffee brewers in which the roasting aromas may be most pleasant, where the ambient presence of the roasting aromas may dramatically enhance the flavor experience, where the preparation time may be greatly reduced and the freshness of the brewed coffee product may be maximized.

(23) Additionally, the above methods permit the brewer and consumer to maximally experience the sweet aromas of the roasting and brewing process and for some of the aromas to be captured freshly in the brewed coffee product.

(24) Please refer to FIG. 2: In a preferred embodiment, the shown brewing device is a combination of roaster and brewer (roasting brewer) comprised of three main assemblies: Water heating assembly 201 is shown atop a roasting and brewing assembly 202, above and in contact with coffee pot assembly 203. Water heating assembly 201 is comprised of containment vessel 204, heating and water temperature controller sub-assembly 205 and water release valve assembly 206. Vessel 204 contains brew water 211 in preparation for brewing.

(25) In a preferred embodiment, coffee pot assembly 203 is comprised of main coffee vessel 207, preferably glass, lid assembly 209 with aperture 228 and handle assembly 210. Coffee service vessel assembly 203 preferably sits atop a warming plate assembly 208.

(26) In a preferred embodiment, heating element 220 raises the temperature of forced air expelled from fan 221 and eccentrically ported through aperture 222, raising the internal air pressure of roasting container 230 so that the air cycles along swirl path 223, circling around the central axis of the roasting container 230 and traveling downward. In some embodiments, the air travels in a helical path downward through the ground coffee after entering the roasting container 230. Coffee grounds roasting pack assembly 224 lies at the bottom of roasting container 230. Higher-pressure heated air passes evenly diffusing through the upper surface of roasting pack assembly 224 and through primary roasted ground coffee package 237 towards the lower pressure ambient environment. Preferably, the upper surface of the roasting pack assembly 224 is comprised of a material that will not substantially degrade when exposed to roasting hot air, typically in excess of 400 degrees Fahrenheit and sometimes near 451 degrees Fahrenheit.

(27) Wafting smoke and aroma particles 231 travels paths 225 through aroma and brew guide vessel 226, in contact with coffee pot lid 209 along a contact 227, through lid aperture 228 into coffee service vessel 207. Some of the coffee smoke and vapors precipitate at the inside of vessel 207 as typified by site 240. Other smoke particles may escape through pour spout aperture 233 along path 232 releasing smoke and aroma 235 into the ambient atmosphere.

(28) Please refer to FIG. 3: At the appropriate time and temperature, heated water 211 in containment vessel 204 is released through valve assembly 206 into the roasting and brewing assembly 202. Heated water 302 pools above primary roasted ground coffee package 237 in pool 303. Brewed coffee 304 drips from primary roasted ground coffee package 237 into aroma and brew guide vessel 226 whilst absorbing freshly occurring smoke and aroma 231.

(29) Brewed coffee 304 drips into coffee service vessel 207, pooling as brewed coffee 305 whilst continuing to absorb deposits and aromas 231 from the air and sides of vessel 207. Some fresh brewing aromas and remaining roasting aromas 235 may escape along path 232 into the ambient environment.

(30) Please refer to FIG. 4A: Primary roasted ground coffee package 237 is comprised of upper filter mesh 401 connected to lower filter body 403 along seam 407, containing ground primary roasted coffee product. In an exemplary embodiment, the filter mesh 401 would be metallic, but it may be ceramic, plastic or a suitable composite material. Primary roasted ground coffee package 237 preferably sits in roasting container 230 atop rim seating ledge 409. Preferably, upper filter mesh 401 is comprised of a material that will not substantially degrade when exposed to roasting hot air, typically in excess of 400 degrees Fahrenheit and sometimes near 451 degrees Fahrenheit.

(31) In an exemplary embodiment, roasted coffee 405 is stratified, with a deeper roast in the upper (inner) stratum varying to a lighter roast in the lower (outer) stratum.

(32) Please refer to FIG. 4B: Primary roasted ground coffee package 237 is tilted to show the lower filter body 403. In an exemplary embodiment, the filter body 403 would be metallic, but it may be ceramic, plastic or a suitable composite material.

(33) Please refer to FIG. 5A: Primary roasted loose ground coffee 505 sits in reusable lower filter tray 503 within vessel 230 atop vessel rim 409. In an exemplary embodiment, the lower filter tray 503 would be metallic, but it may be ceramic, plastic or a suitable composite material.

(34) Reusable upper filter tray 501 sits atop lower tray 503 to contain primary roasted loose ground coffee 505. In an exemplary embodiment, the upper filter tray 501 would be metallic, but it may be ceramic, plastic or a suitable composite material. In an exemplary embodiment, coffee 505 is roasted evenly throughout. Preferably, upper filter tray 501 is comprised of a material that will not substantially degrade when exposed to roasting hot air, typically in excess of 400 degrees Fahrenheit and sometimes near 451 degrees Fahrenheit. In an exemplary embodiment, coffee 505 is roasted evenly throughout.

(35) Please refer to FIG. 5B: Reusable metallic lower filter tray 503 is tilted to show the lower filter at bottom. In an exemplary embodiment, the lower filter tray 503 would be metallic, but it may be ceramic, plastic or a suitable composite material.

(36) Having shown and described preferred embodiments, those skilled in the art will realize that many variations and modifications may be made to affect the described embodiments and still be within the scope of the claimed invention. Additionally, many of the elements indicated above may be altered or replaced by different elements which will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.