Beverage Capsule

Abstract

Single-serve ingredient packages made from materials which are biodegradable and compostable and which are derived from readily renewable resources environmentally advantageous and may be used to brew beverages such as coffee, tea, and cocoa; the capsule comprising an outer sleeve, a cup disposed in the outer sleeve, a multilayered filtering element disposed in the cup that divides the interior space of the cup into first and second chambers, a lid that hermetically seals the first chamber of the cup, and a beverage medium that is disposed within the first chamber of the cup.

Claims

1. A beverage capsule comprising: (a) a cup comprising a rim that circumscribes an opening, a base, and a sidewall that extends between the base and the rim; (b) a filtering element received into the cup, the filtering element comprising a rim that circumscribes an opening, a base, and a sidewall extending there between, the sidewall having a first section that is coupled to one or more crests of the cup sidewall and a second section terminating at the base, the second section comprising at least a portion that is inwardly tapered, the base of the filtering element being coupled to the base of the cup, and the rim of the filtering element being coupled to the rim of the cup, the filtering element dividing the cup into a first chamber and a second chamber; (c) a beverage ingredient received into the first chamber of the cup; and (d) a cover coupled to the filtering element rim and covering the filtering element opening, thereby sealing the beverage ingredient within the beverage capsule, the cover being pierceable.

2. The beverage capsule according to claim 1, further comprising an outer sleeve that covers the cup.

3. The beverage capsule according to claim 2, wherein the outer sleeve is made of a biodegradable material.

4. The beverage capsule according to claim 3, wherein the biodegradable material is selected from the group consisting of: bamboo, sugarcane, bagasse, straw, switchgrass, and a combination thereof.

5. The beverage capsule according to claim 1, wherein the cup, the filtering element, and the cover is made of a biodegradable material.

6. The beverage capsule according to claim 5, wherein the biodegradable material is selected from the group consisting of polylactic acid, crystallized polylactic acid, a polylactic aliphatic copolymer derived from a readily renewable resource, and a combination thereof.

7. The beverage capsule according to claim 6, wherein the readily renewable resource is corn starch or sugar cane.

8. The beverage capsule according to claim 5, wherein the cover is formed by extruding polylactic acid onto a cellulose-based paper stock.

9. The beverage capsule according to claim 1, wherein the filtering element is made from two or more filtering sheets, each sheet comprising a grain pattern, wherein the grain patterns of the two or more filtering sheets are oriented relative to one another in a non-parallel arrangement.

10. The beverage capsule according to claim 9, wherein the grain patterns of the two or more filtering sheets are oriented orthogonal to one another.

11. The beverage capsule according to claim 1, wherein the filtering element is unwoven.

12. The beverage capsule according to claim 1, wherein the filtering element is undrawn.

13. A method of manufacturing a beverage capsule, comprising: (a) providing a cup comprising a rim that circumscribes an opening, a base, and a sidewall that extends between the base and the rim; (b) inserting a filtering element into the cup, the filtering element comprising: (i) a rim that circumscribes an opening; (ii) a base; and (iii) a sidewall extending there between, the sidewall having a first section and a second section, the second section terminating at the base and having at least a portion that is inwardly tapered; (c) coupling: (i) the filtering rim to the cup rim; (ii) one or more crests of the cup sidewall to the filtering element; and (iii) the base of the filtering element to the base of the cup; the filtering element separating the cup into a first chamber and a second chamber; (d) disposing a beverage ingredient into the first chamber of the cup; and (e) sealing the beverage capsule with a lid.

14. The method according to claim 13, wherein the coupling is by heat sealing or sonic welding.

15. A cartridge for use in forming a beverage, the cartridge comprising: an outer sleeve with sidewalls diverging upwardly from an opening at the base to an upper rim and an opening; an inner cup comprised of crystallized polylactic acid (CPLA); a lid comprised of PLA extruded onto a cellulose-based paper stock that is welded to the uppermost rim of the container; and a filter element comprised of two or more permeable sheets of unwoven and undrawn PLA which are layered such that their grains lie perpendicular to each other (straight grain and cross grain), die cut and pressed into a heated male/female mold, the resulting frustoconical/conical filter element includes incongruent folds along its sides which are laminated in place during the molding process, the upper portion of said filter element is frustoconical and coincident with the sidewalls of the sleeve and the lower portion of said filter element tapers gradually into a substantially cone shaped bottom, said filter element spaced vertically from the container bottom wall.

16. A method of manufacturing a cartridge for use with a beverage brewing machine, comprising: attaching the upper rim of the filter by either heat sealing or sonic welding, to the uppermost rim of the sleeve, which is itself welded to the outer fiber container; welding the filter element to the upper portion of the sleeve sidewall; subdividing the interior space of the container through the use of a filter into two distinct chambers such that when liquid enters first chamber of the interior space (e.g. that interacts with beverage medium), it flows through the filter element and toward the second chamber; and providing a beverage medium arranged to interact with liquid introduced into the container to form a beverage.

17. A method of utilizing a cartridge for making a beverage, comprising: a lid attached to the uppermost rim of the container is pierced by the upper piercing element to allow heated liquid to enter the first chamber for infusion with the beverage medium; a container is pierced at the bottom by a piercing element to allow the beverage medium to exit the cartridge; a filter element, vertically spaced from the bottom of the container, safeguards the filter from being inadvertently punctured by the piercing element during the brewing process; wherein the beverage machine is arranged so that the mixture or solution then exits the second chamber through the base via the extractor into a coffee mug or the like so that the beverage may be consumed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] In the accompanying drawings, which illustrate one or more aspects and embodiments of the disclosure:

[0014] FIG. 1 is a cross-sectional side view of a beverage capsule according to an embodiment, the capsule comprising an outer sleeve, a cup disposed in the outer sleeve, a filter disposed in and coupled to the cup, and a lid that seals the beverage capsule.

[0015] FIG. 2 is a cross-sectional side view of the beverage capsule of FIG. 1, wherein the base of the cup is punctured by a fluid extracting element, and the lid is punctured by a fluid injecting element.

[0016] FIG. 3 is an exploded perspective view of the beverage capsule of FIG. 1.

[0017] FIG. 4 is a cross-sectional top view of the beverage cartridge of FIG. 1 along cross-sectional slice 1-1.

[0018] FIG. 5 is a perspective view of the base of the outer sleeve of the beverage capsule of FIG. 1.

[0019] FIG. 6 is an exploded perspective view of an unformed filtering element for use in a beverage capsule, the filtering element comprising two layers.

[0020] FIG. 7 is an exploded view of the manufacturing process of forming the filtering element of FIG. 6.

[0021] FIG. 8(a) is a perspective view of the filtering element of FIG. 6, wherein the filtering element is formed into an illustrative design according to the process of FIG. 7.

[0022] FIG. 8(b) is a perspective view of the filtering element of FIG. 6, wherein the filtering element is formed into another illustrative design according to the process of FIG. 7.

[0023] FIG. 8(c) is a perspective view of the filtering element of FIG. 6, wherein the filtering element is formed into another illustrative design according to the process of FIG. 7.

[0024] FIG. 8(d) is a perspective view of the filtering element of FIG. 6, wherein the filtering element is formed into another illustrative design according to the process of FIG. 7.

[0025] FIG. 8(c) is a perspective view of the filtering element of FIG. 6, wherein the filtering element is formed into another illustrative design according to the process of FIG. 7.

[0026] FIG. 8(f) is a perspective view of another embodiment of the filtering element, wherein the filter element does not include a rim.

[0027] FIG. 9 is a cross-sectional top view of the filtering element depicted in any one of FIGS. 8(a) to 8(e), along cross-sectional slice 8-8.

[0028] FIG. 10 is a cross-sectional side view of a beverage capsule according to another embodiment, the capsule comprising an outer sleeve, a cup disposed in the outer sleeve, a filter disposed in and coupled to the cup, and a lid that seals the beverage capsule, wherein the base of the cup comprises an indentation.

DETAILED DESCRIPTION

[0029] The present disclosure relates to a beverage capsule and a method of manufacturing thereof.

[0030] Directional terms such as top, bottom, upwards, downwards, vertically, and laterally are used in the following description for the purpose of providing relative reference only, and are not intended to suggest any limitations on how any article is to be positioned during use, or to be mounted in an assembly or relative to an environment. The use of the word a or an when used herein in conjunction with the term comprising may mean one, but it is also consistent with the meaning of one or more, at least one and one or more than one. Any element expressed in the singular form also encompasses its plural form. Any element expressed in the plural form also encompasses its singular form. The term plurality as used herein means more than one, for example, two or more, three or more, four or more, and the like.

[0031] As used herein, the terms comprising, having, including and containing, and grammatical variations thereof, are inclusive or open-ended and do not exclude additional, un-recited elements and/or method steps. The term consisting essentially of when used herein in connection with a composition, use or method, denotes that additional elements, method steps or both additional elements and method steps may be present, but that these additions do not materially affect the manner in which the recited composition, method or use functions. The term consisting of when used herein in connection with a composition, use or method, excludes the presence of additional elements and/or method steps.

[0032] As used herein, the term biodegradable means a substance or object capable of being decomposed by bacteria or other living organisms.

[0033] As used herein, the term compostable means a substance that according to the European Standard EN13432 states (i) that a material is deemed to be compostable by measuring the actual metabolic conversion of the material into carbon dioxide; (ii) a material is characterized as biodegradable if in less than six months, the material has biodegraded by 90%; (iii) the material also has to pass a composting test (EN 14045) where the material is sieved with a 2.0-mm sieve after 3 months, the residue can be no higher than 2 mm. This must be less than 10% of the material's original mass; (iv) there must be an absence of negative effects on the composting process and low levels of heavy metals; and (v) the material has to pass the plant growth test (OECD 208, modified) where the test material must be the same as the control compost. All of these various requirements must be simultaneously met to be defined as compostable and meet the European Standard EN 13432. According to section 6.2 of the ASTM D6400, Standard Specification for Compostable Plastics, plastic products are deemed to have disintegrated during composting if after twelve weeks in a controlled composting test, no more than 10% of its original dry weight remains after sieving on a 2.0-mm sieve. The compositing conditions are generated in a laboratory thermophilic by performing Test Method D5338 without CO2 trapping component, or ISO 16929.

[0034] As used herein, the term readily renewable material means a material that is derived from plants such as cellulose, chitosan, lignin or vegetable oil. These materials have grow cycles within a one-year period and include bagasse and bamboo.

[0035] As used herein, the term about means within 10% of the stated value.

[0036] Beverage Capsule

[0037] Referring to FIGS. 1 to 9, and according to an embodiment of the disclosure, there is a beverage capsule 100 comprising an outer sleeve 110, a cup 120 disposed in and coupled to the outer sleeve 110, a filtering element 130 disposed in and coupled to the cup 120, and a lid 140 coupled to the filtering element and for sealing the beverage capsule 100. The beverage capsule 100 may be a single-serve beverage capsule.

[0038] The outer sleeve 110 comprises a rim 112 that circumscribes an opening 114. The outer sleeve further comprises a base 116, and a sidewall 118 that extends between the base 116 and the top rim 112. The components of the outer sleeve 110 define an interior volume that is accessed through the opening 114. An aperture 116a is disposed in the base 116. As contemplated in this embodiment, the aperture 116a is circular. However, in other embodiments, the area of the aperture 116a relative to the area of the base 116 may vary and may be any suitable shape known in the art. In other embodiments, the aperture is not present.

[0039] The outer sleeve 110 imparts structural integrity to the beverage capsule 100, and may act as a thermal insulator. For example, the outer sleeve 110 may act as an insulator which facilitates safe removal of the beverage capsule 100 from a brewing machine, after the brewing process when the beverage capsule may still be hot and wet. As contemplated in this embodiment, the outer sleeve 110 is manufactured a biodegradable and/or compostable fibrous material including, but not limited to, bamboo, sugarcane, bagasse, straw, switchgrass, and a combination thereof. However, in other embodiments, the outer sleeve 110 may be manufactured of any suitable material known in the art.

[0040] The outer sleeve 110 comprises a draft angle 119 in the range of 6 to 10 degrees from the vertical. A draft angle 119 that falls within the foregoing range of angles allows the outer sleeve 110 to be demolded without sustaining damage during its manufacturing process. As depicted in this embodiment, the outer sleeve 110 has a frustoconical shape. In other embodiments, the outer sleeve may have any suitable shape that is complementary to any restrictions of a brewing machine. The cup 120 comprises a rim 122 that circumscribes an opening 124. The cup 120 further comprises a base 126 and a sidewall 128 that extends between the base 126 and the top rim 122. A plurality of latitudinal channels 129 defined by crests 129a and troughs 129b form a part of the sidewall 128. The plurality of channels 129 extends between the top rim 122 and the base 126. The latitudinal channels 129 impart structural rigidity to the beverage capsule 100, act as guiding channels for directing aqueous media towards the base 126 of the cup 120, and also provide periodically distributed support points along the filter surface 129a to prevent the liquid-saturated filter 130 from becoming stuck to the sidewall 128 of the cup 120, therefore maintaining liquid permeability along the frustoconical portion 138a of the filter 130.

[0041] The components of the cup 120 define an interior volume that is accessed through the opening 124.

[0042] The cup 120 is disposed in the interior volume of the outer sleeve 110 such that: (i) the bottom surface of the cup rim 122 is contiguous and coupled (for example, mechanically or thermally) to the top surface of the outer sleeve rim 112; (ii) the plurality of troughs 129b is contiguous and coupled to the inner surface of outer sleeve sidewall 118, as depicted in FIG. 4; and (iii) at least a portion of the base 126 of the cup 120 extends through the aperture 116a of the outer sleeve 110, as depicted in FIG. 1. In other embodiments, the plurality of troughs 129b may not be contiguous coupled to the inner surface of outer sleeve sidewall 118. In other embodiments, the base 126 of the cup 120 may not extend through the aperture 116a of the outer sleeve 110. In other embodiments where the aperture 116a is not present, the outer surface of the base 126 is coupled to the inner surface of base 116.

[0043] As contemplated in this embodiment, the cup 120 is manufactured of a biodegradable and compostable material such as, but not limited to, PLA, crystallized polylactic acid (CPLA), a polylactic aliphatic copolymer derived from a readily renewable resource such as corn starch or sugar cane, or a combination thereof. However, other biodegradable and compostable materials meeting the temperature and composting requirements set forth above, or other materials that are not resistant to microbial, bacterial, fungi, or actinomycete breakdown, may also be used in the formation of the cup 120. In other embodiments, the cup 120 may be manufactured of any material known in the art.

[0044] The filtering element 130 comprises two sheets of filter material 130a, 130b that are formed into a desired design such as, but not limited to, any one of the illustrative designs depicted in FIGS. 8(a) to 8(e). Each sheet of filter material 130a, 130b comprises a grain pattern. The sheets of filter material 130a, 130b may be unwoven or woven. As contemplated in this embodiment, the sheets of filter material 130a, 130b are unwoven and undrawn and made of a biodegradable and compostable material such as, but not limited to, PLA. In other embodiments, the filtering element 130 may be made of any suitable material known in the art. In other embodiments, the filtering element 130 may be made of more than two sheets of filter material.

[0045] As depicted in FIGS. 3 and 8(a) to 8(e), a formed filtering element 130 comprises a rim 132 circumscribing an opening 134, a base 136, and a sidewall 138 extending between the base 136 and the rim 132. The sidewall 138 comprises a top section 138a and a bottom section 138b. The components of the filtering element 130 define an interior volume that is accessed through the opening 134. It is contemplated that dry beverage ingredient 50 such as, but not limited to, coffee, tea and cocoa, is disposed within the interior volume of the filtering element 130. As depicted in FIG. 8f, in another embodiment, the filter may not include a rim.

[0046] The filtering element 130 is disposed in the interior volume of the cup 120 such that: (i) the bottom surface of rim 132 is contiguous and coupled (for example, mechanically or thermally) to the top surface of rim 122 of the cup 120; (ii) portions of the top section 138a are contiguous and coupled (for example, mechanically or thermally) to one or more of crests 129a of the cup 120, for example all of the crests as depicted in FIG. 4; and (iii) at least a portion of bottom section 138b, for example base 136 as depicted in FIG. 1, is contiguous and/or coupled to the base 126 of the cup 120. Coupling the filtering element 130 to at least one of crests 129a reduces the likelihood that the filtering element 130 may be displaced within the beverage capsule 100. In other embodiments, the bottom section 138b may not be contiguous or coupled to the base 126 of the cup 120. In other embodiments, the top section may not be contiguous and coupled to the top surface of the rim 122 of the cup 120.

[0047] The top section of the filter 138a is generally shaped to be contiguous with the crests 129a of the cup 120. Bottom section 138b is tapered inwardly and away from the sidewall 128 of the cup 120, as depicted in any one of FIGS. 8(a) to 8(e), such that the bottom section 138b avoids contact with, and avoids being punctured by, the fluid extracting piercing element 200, as depicted in FIG. 2. Also as depicted in FIG. 2, at least a portion of the bottom section 138b resides below the height of the tip 200a of the fluid extracting piercing element 200. It is believed that this portion of additional volume provided by bottom section 138b increases the quantity of dry ingredient 50 that may be disposed within the beverage capsule 100.

[0048] When the filtering element 130 is disposed within the interior volume of the cup 120, filtering element 130 divides the interior volume of the cup 120 into two chambers: a first chamber 120a extending between the opening 124 and the bottom section 138b; and a second chamber 120a extending between the bottom section 138b and the base 126 of the cup 120.

[0049] The lid 140 seals the beverage capsule 100, and is contiguous and coupled to the top surface of rim 132 of filtering element 130. The lid 140 may be formed from a cellulosic or other plant-based material. As contemplated in this embodiment, the lid 140 is formed of a biodegradable and compostable material such as, but not limited to, PLA that is extruded onto a cellulose-based paper stock.

[0050] Referring to FIG. 10 and according to another embodiment, there is a beverage cartridge 100 comprising an outer sleeve 110, a cup 120 disposed in the outer sleeve 110, a filtering element 130 disposed in and coupled to the cup 120, and a lid 140 for sealing the beverage capsule 100.

[0051] The cup 120 comprises a base 126. The base 126 comprises an indentation 126a. The base of filtering element 130 is contiguous and/or coupled to the top of the indentation 126a. Without being bound by theory, it is believed that the indentation 126a assists in distributing downward pressure of the filtering element 130 more evenly along the base 126 of the cup 120 as liquid media passes through the filter element 130 and into the second chamber 120b.

[0052] Manufacturing of the Filtering Element 130

[0053] Unwoven filter material 130a, 130b are oriented relative to one another such that the grain patterns on the unwoven filter material 130a, 130b are either parallel or not parallel. The grain patterns of the unwoven filter material 130a, 130b are preferably oriented 90 relative to each other. However, the grain patterns of the unwoven filter material 130a, 130b may be oriented anywhere between 0 and 90 relative to each other, such as, but not limited to between about 10 and about 90, about 20 and about 90, about 30 and about 90, about 40 and about 90, about 50 and about 90, about 60 and about 90, about 70 and about 90, about 80 and about 90. Without being bound by theory, it is believed that through orienting the grain patterns in a non-parallel or orthogonal arrangement, the two sheets of unwoven filter material 130a, 130b reinforce each other.

[0054] Referring to FIG. 7, the two unwoven filter material 130a, 130b are fashioned into a desired shape, such as through die cutting or any comparable process known in the art, and are thermally coupled to each other through thermally pressing or annealing in a heated male and female mold 400. The two unwoven filter materials 130a, 130b are thermally pressed together for approximately 3-5 seconds, at a temperature of approximately 80 to 150 degrees Celsius, and with a reasonably sufficient amount of pressure.

[0055] The resulting filtering element 130 includes incongruent folds 132, which are laminated in place during the thermal pressing or annealing process. The incongruent folds 132 provide structural integrity to the filtering element 130. The two unwoven filter material 130a, 130b remain substantially undrawn during the molding process.

[0056] Manufacturing of the Beverage Capsule 100

[0057] The outer sleeve 110 and cup 120 are provided, and the cup 120 is inserted into the outer sleeve 110. The rims 112 and 122 are thermally coupled or sonically welded together, the troughs 129b may be thermally coupled or sonically welded to the inner sidewall 118 of the outer sleeve 110. In other embodiments, the cup 120 may be coupled to the outer sleeve 110 by other methods known in the art.

[0058] The filtering element 130 is disposed into the interior volume of the cup 120. The rim 132 of the filtering element 130 is coupled to the rim 122 of the cup 120 by heat sealing or sonic welding. The first section 138a of filtering element 130 is thermally coupled to the crests 129a of the cup 120 by sonic welding. By coupling the filtering element 130 to the crests 129a and the base 126, the likelihood of the filtering element 130 being displaced during use of the beverage capsule is reduced. In other embodiments, the filtering element 130 may be coupled to the cup 120 by other methods known in the art.

[0059] The foregoing coupled components of the beverage capsule 100 are then placed in an anaerobic flushing chamber wherein a beverage ingredient 50 is placed in the first chamber 120a of the beverage capsule 100. Lid 140 is then hermetically sealed to rim 132, thereby covering opening 134 and sealing beverage ingredients 50 within the beverage capsule 100.

[0060] Use of the Beverage Capsule 100

[0061] The beverage capsule 100 is introduced into a brewing machine (not shown). The brewing machine is activated, and a fluid injecting element 300 of the brewing machine punctures the lid 140 of the beverage capsule 100 and introduces a brewing medium (e.g. hot water) into the first chamber 120a of the beverage capsule, the first chamber 120a containing the brewing ingredient 50. The brewing medium mixes with the brewing ingredient 50 to form a brewing mix. The brewing mix percolates through the filtering element 130 and into the second chamber 120b, at least some of which is guided along the channels 129 into the second chamber 120b. A fluid extracting element 200 penetrates the base 126 of the beverage capsule 100, entering the second chamber 120b, but not contacting the filtering element 130 or entering into the first chamber 120a. The brewing mix is then extracted from the beverage capsule 100 by the fluid extractor 200, and eventually dispensed as a beverage.

[0062] It is contemplated that any part of any aspect or embodiment discussed in this specification can be implemented or combined with any part of any other aspect or embodiment discussed in this specification. While particular embodiments have been described in the foregoing, it is to be understood that other embodiments are possible and are intended to be included herein. It will be clear to any person skilled in the art that modification of and adjustment to the foregoing embodiments, not shown, is possible.