Abstract
A Gasket for a beverage pod, comprising: A beverage pod comprising an exterior portion and an interior portion, A gasket disposed about the exterior portion of the beverage pod, wherein the gasket provides a seal between a brewing device and the exterior portion of the beverage pod, the seal thereby providing a means to maintain a pressure differential between the interior portion of the beverage pod and the exterior portion of the beverage pod.
Claims
1. A Gasket for a beverage pod, comprising: A beverage pod comprising an exterior portion and an interior portion, A gasket disposed about the exterior portion of the beverage pod, wherein the gasket provides a seal between a brewing device and the exterior portion of the beverage pod, the seal thereby providing a means to maintain a pressure differential between the interior portion of the beverage pod and the exterior portion of the beverage pod.
Description
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0019] FIG. 1: Illustrates a Compostable Beverage Pod, according to an embodiment.
[0020] FIG. 2: Illustrates a Compostable Gasket, according to an embodiment.
[0021] FIG. 3: Illustrates a Pod with Gasket, according to an embodiment.
[0022] FIG. 4: Illustrates a Embodiment, according to an embodiment.
[0023] FIG. 5: Illustrates a Method, according to an embodiment.
DETAILED DESCRIPTION
[0024] FIG. 1 is a system for a Compostable Beverage Pod. This system comprises of Beverage pods, or beverage cartridges, are containers, pods, capsules, etc., for use in a beverage brewing machine, such as a coffee maker. They may include one or more of, a beverage medium that is either soluble or insoluble, one or more filters and a first portion in which liquid is passed into and a second portion through which liquid passes out of the cartridge. In some instances, they are portioned beverage packages often contain a water-soluble material, to make a drink such a hot chocolate, chai tea, etc. These portioned packages can be pouches as well as pods for beverage brewing machines, element 102. Beverage cartridges can contain a number of components, including pod lid, capsule lid, or cartridge lid, is one component of a beverage pod, often made of foil, that is sealed to the pod, cartridge, capsule, etc., so as to contain the beverage medium. A compostable capsule lid may be comprised of, for example a spun bond PLA web film (which may contain a proportion of PHA, in some embodiments), a cellulose paper film, etc., element 104. The pod bond is the connection between any two of the capsule lid, capsule outer shell, and capsule interior. This bond can be mechanical or chemical, and such as adhesives, heat sealing, ultrasonic welding, etc. The pod bond and the filter bond can be in one place or separately depending upon the use case. A filter bond is a type of capsule bond that binds the filter medium to a portion of the capsule, such as by ultrasonic welding, adhesives, thermal sealing, etc., element 106. A pod exterior, or capsule, or cartridge is the outer shell of the beverage cartridge. The exterior can be made of plastic (especially compostable plastic, such as PLA, PHA, or combinations thereof), cellulose, etc. It has similar properties to other thermoplastic polymers such as polypropylene (PP), polyethylene (PE), or polystyrene (PS). This allows it to serve as a biodegradable alternative for coffee pods. It can also be made from polyhydroxyalkanoates (PHAs), which are a biodegradable polyester produced through bacterial fermentation of sugar or lipids. They can be used as alternatives to other synthetic plastics. The mechanical properties of PHAs can be modified for a given use case by blending it with other biodegradable polymers, such as PLAs. They can also be made from poly(L-lactide) (PLLA), which is a polymer that is also biodegradable and compostable. The material may be used to form various aspects of the beverage cartridge. PLLA is also readily renewable, typically made from fermented plant starch such as from corn, cassava, sugarcane, or sugar beet pulp. Cellulose fibers are fibrous materials made from plant materials such cotton, flax, wood pulp, etc. They provide a biodegradable filter material that could be used in coffee pods. Other materials that are biodegradable plastic alternatives include petroleum based plastics such as, Polyglycolic acid (PGA), Polybutylene succinate (PBS), Polycaprolactone (PCL), Polyvinyl alcohol (PVOH) and Polybutylene adipate terephthalate (PBAT), element 108. In some embodiments, the compostable pod may comprise at least one compostable gasket, element 110. The compostable gasket may be, for example, a flat ring, similar in share to a mechanical washer, of cellulose fiber with a layer of PLA on one side of the flat ring. The side of the compostable gasket with a layer of PLA may be placed against the underside of the upper lip of the beverage pod, as shown in FIG. 1. The PLA side of the compostable gasket may then be fused to the capsule 108, using any such methods as described by the pod bond 106. In an exemplary embodiment, the compostable gasket 110 is fused to the capsule 108 using ultrasonic welding. A filter guard, or faceplate, is a solid structure integrated into a beverage pod that prevents the outlet piercing element from creating a path for the insoluble beverage material from inside the filter to the outlet. In some embodiments, the capsule interior may include integrated features to act as a filter guard, removing the requirement for a discrete component, element 112. A filter is a medium, such as spun bond PLA web, paper (cellulose), cloth or metal, that is used to prevent an insoluble beverage material from leaving the beverage pod and entering the beverage brewing machine or the beverage. Filters can be symmetrical (e.g., fluted), or asymmetrical (e.g., pleated), element 114. Beverage material is the material used to produce a brewed beverage, such as coffee grounds, tea, or a mix beverage where the beverage material is soluble, such as hot chocolate. Beverage material may include any flavorings, nutritional content (e.g., any oils, nutritional supplements, active ingredients such as pharmaceuticals, cannabinoids, etc.), alcohol, coloring, or any other composition which has an effect on the final beverage, element 116. Beverage brewing machines for brewing portioned beverages from pre-packed beverage pods exist for a variety of beverages made from a beverage material that is either insoluble, such as coffee, or soluble, such as hot chocolate. A beverage brewing machine will typically contain many other components, such as, for example, a heating element, a liquid reservoir or plumbing component, a liquid pump, an exterior chassis, a controller for the brewing process, a display or indicator lights and sounds, a user interface including buttons or a touchscreen, a tray to catch spillage, etc. For the purposes of description, it is assumed a beverage brewing machine contains all components necessary to accomplish the beverage brewing process, though specific reference to beverage brewing machine components may only be made to those components which come into direct contact with the beverage pod, such as the brewing chamber, a fluid injecting component, and a fluid extracting component, element 118. A beverage brewing machine will contain the following elements: A beverage brewing machine will contain the following elements: A fluid source that supplies the liquid, usually water, to the brewing machine for producing the desired beverage, element 120. A brewing chamber lid that opens to allow a new pod to be added to the machine, and in many of the most common embodiments of a beverage brewing machine, the chamber lid contacts the fluid source to the brewing pin, but the fluid source does not have to be in the brewing chamber lid, element 122. A brewing pin member, or fluid injecting component, that typically has a piercing element to puncture the beverage pod lid, that provides a liquid, typically hot water, to mix with the beverage medium to create the beverage, element 124. A brewing chamber, receptacle, or sieve holder, into which the beverage pod is placed so that a beverage can be brewed, element 126. An outlet, or fluid extracting component, that typically has a piercing element to puncture the bottom of the beverage pod to allow the brewed beverage to leave the brewing chamber. Depending upon the embodiment, it may pierce or deform other components of the beverage pod, element 128. In an alternative embodiment of the present invention, the compostable gasket may be located on the lower lip of the capsule 108, shown as element 130. In such embodiments, the gasket may be fused with the lower lip using any method described as the pod bond 106. The gasket 130 may provide improved sealing through compression, and in some embodiments, may be used in isolation or in conjunction with the gasket 110.
[0025] Functioning of the “Compostable Gasket” will now be explained with reference to FIG. 2. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.
[0026] FIG. 2 shows an exemplary embodiment of the compostable pod gasket 110. In some embodiments, the compostable pod gasket may incorporate various materials to facilitate sealing in the brewing chamber 126 and achieve material fusion with the pod capsule 108. In one embodiment, a first side of the compostable pod gasket 110 may comprise a compostable thermoplastic coating, such as PLA, PHB, or other PHAs, is shown as element 202. The thermoplastic coating may facilitate fusion with the pod capsule 108 through any means describe as the pod bond 106. In one instance, the gasket 110 may be fused with the pod capsule 108 by means of ultrasonic welding. Ultrasonic welding is a process by which high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld. In the present invention, the ultrasonic welding may facilitate a weld between the PLA surface of the gasket 110 and the pod exterior 108. The gasket may also be comprised, in some embodiments, of a compressible material, such as cellulosic fiber shown as element 204. The gasket 110 functions as a mechanical seal which fills the space between two or more mating surfaces, e.g., the exterior of the pod capsule 108 and the brew chamber 126, generally to prevent leakage from or into the joined objects while under compression. Cellulose fiber is a compostable, plant based material capable of providing a seal when placed under compression. The compressed cellulose thereby providing a seal that increases the potential pressure of brewing liquid into the beverage pod 102. Achieving high fluid pressure is necessary for proper brewing of certain beverages, e.g., espresso.
[0027] Functioning of the “Pod with Gasket” will now be explained with reference to FIG. 3. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.
[0028] FIG. 3 shows an exemplary pod with a compostable pod gasket. Element 302 is a compostable pod with a compostable pod gasket. The compostable pod with a compostable pod gasket 302 comprises a pod lid 304, a pod bod 306, a pod exterior 308 and a compostable pod gasket 302. Element 304 is a pod lid. Beverage cartridges can contain a number of components, including pod lid, capsule lid, or cartridge lid, is one component of a beverage pod, often made of foil, that is sealed to the pod, cartridge, capsule, etc., so as to contain the beverage medium. A compostable capsule lid may be comprised of, for example a spun bond PLA web film (which may contain a proportion of PHA, in some embodiments), a cellulose paper film, etc. In operation the pod lid 304 may be pierced by the brewing pin 124 to allow the fluid source 120 to introduce brewing liquid into the interior of the compostable pod 302. In the present invention, the brewing liquid may be ideally introduced at a specific pressure, e.g., 9 bar. The pressurization of the brewing liquid requires a tight seal between the compostable pod 302 and the brewing chamber 126. Element 306 is a pod bond. The pod bond is the connection between any two of the capsule lid, capsule outer shell, and capsule interior. This bond can be mechanical or chemical, and such as adhesives, heat sealing, ultrasonic welding, etc. The pod bond and the filter bond can be in one place or separately depending upon the use case. A filter bond is a type of capsule bond that binds the filter medium to a portion of the capsule, such as by ultrasonic welding, adhesives, thermal sealing, etc. The bod bond may also apply to other elements of the compostable pod, e.g., the compostable pod gasket 310 may also, in some embodiments, have a pod bod 306 to the pod exterior 308. Element 308 is the pod exterior, which may be, for example, a plant-based thermoplastic polymer such as PLA. In some embodiments, the pod gasket 310 may have a pod bond 306 to the pod exterior 308. In some embodiments, the pod exterior 308 may be comprised of the same or a similar thermoplastic polymer, such as PLA, used to coat at least one side of the pod gasket 310, as shown in FIG. 2 as element 202. In such embodiments, the pod bond 306 may be, for an example, an ultrasonic weld between the coated side of pod gasket 310 and pod exterior 308. Element 310 is a compostable pod gasket on the underside of the upper lip of the compostable pod with a compostable pod gasket 302. Element 312 is a compostable pod gasket on the underside of the lower lip of the compostable pod with a compostable pod gasket 302. In some embodiments, the compostable pod with compostable pod gasket may have on or more pod gaskets 310. The pod gaskets 310 may be placed, for example, at contact points with the brewing chamber 126. In some embodiments of the present invention, at least a portion of the pod gasket is comprised of a compressible material, such as cellulosic fiber. The gasket may then be compressed upon insertion into a beverage brewing device. The compressed gasket creates a seal between the pod exterior and the brewing chamber 126 of a beverage brewing device. The seal allows the beverage brewing device to provide fluid to the compostable pod with compostable pod gasket 302 at an increased pressure. In some embodiments, the increased fluid pressure may provide improved extraction for certain brewed beverage, which may be, for example, espresso or espresso-like beverages. For espresso and espresso-like beverages, fluid pressure up to approximately 9 bars may be required for ideal beverage properties.
[0029] Functioning of the “Embodiment” will now be explained with reference to FIG. 4. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.
[0030] FIG. 4 shows an exemplary embodiment of the Compostable pod with Gasket ring. The compostable pod is shown as element 402, with a compostable pod lid 104 at the top of the image and the gasket ring fused to the underside of the capsule lip shown as element 404. In operation, the Compostable pod 402 may be inserted into the brew chamber 126 of a beverage brewing machine 118. A brew chamber lid 122 may close down upon the brew chamber 126, enclosing the beverage pod 402 inside the brew chamber 126. In some embodiments, the brew chamber lid 122 may cause the gasket ring 404 to become compressed, creating a tight seal about the beverage pod 402 between the inlet 120 and the brewing pin 128. The tight seal increases the fluid pressure from the inlet 120, thus causing improved extraction of the beverage material 116. In some embodiments, the beverage material may be, for example, espresso coffee grounds. It is well known that espresso extraction occurs optimally at high pressure, typically around 9 bar (e.g., 9 times the atmospheric pressure at sea level). In some embodiments, the thickness of the compostable gasket 404 may be selected based, at least in part, on the desired pressure of the beverage material 116 extraction. In other embodiments, the thickness of the compostable gasket 404 may be based, at least in part, on the parameters (e.g., size and dimensions) of the brew chamber 126. In some embodiments, the compostable gasket 404 may be removable to accommodate brew chambers 126 with less tolerance for gasket compression.
[0031] Functioning of the “Method” will now be explained with reference to FIG. 5. One skilled in the art will appreciate that, for this and other processes and methods disclosed herein, the functions performed in the processes and methods may be implemented in differing order. Furthermore, the outlined steps and operations are only provided as examples, and some of the steps and operations may be optional, combined into fewer steps and operations, or expanded into additional steps and operations without detracting from the essence of the disclosed embodiments.
[0032] FIG. 5 shows a method of manufacturing a compostable beverage pod with a compostable gasket. Step 1 is 502 Prepare Gasket; in this step the final gasket is prepared for installation. This may include for example, coating one side of a Cellulose fiber sheet with PLA, and then cutting the gasket shape out of the coated sheet. In some embodiments, a coated cellulose fiber sheet may be provided from a 3rd party supplier. The step may include loading the sheet onto a cutting machine and cutting at least one gasket out of the sheet. Finally, the step may involve loading the prepared gaskets into an installation machine. In one embodiment, the gaskets may be loaded in a single or multiple stacks, allowing the coated side of each gasket to remain in the correct orientation relative to the pod. In such embodiments, the correct orientation relative to the pod may be, for example, any orientation such that the coated side of the gasket is capable of mating with the exterior of the capsule. Step 2 is 504 Prepare Pod; in this step the pod is prepared to receive the gasket. The may include, for example, any steps needed to create the pods final shape to receive the gasket, loading the pods into a gasket installation device, etc. In some embodiments, the pods may be loaded in a single or multiple stacks, allowing the pods to maintain correct orientation relative to the gasket installation device. Step 3 is 506 Install Gasket on Pod, a step where the gasket is placed on the pod in the vicinity of where the gasket will be bonded to the pod. In some embodiments, the gasket may be placed above or below one or more portions of the exterior of the pod, such as, for example, below the upper lip of the pod where the exterior of the pod contacts the brew basket 126 during a beverage brewing process. Step 4 is 508 Create Pod bond with Gasket, a step where the gasket is bonded with the pod exterior. The gasket may be bonded in any method suitable for a compostable or non-compostable beverage pod, such as, for example, adhesive or ultrasonic welding. In some embodiments, the pod bond may be a friction fit, compression fit, screw threading, clip-in, seating the gasket in a groove (typical with O-ring gaskets) or another mechanical means of affixing the gasket without the need for additional energetic or chemical bonding. Step 5 is 510 Complete Pod Assembly, a step where any remaining processes of beverage pod assembly is completed before a final pod is produced. The step may include, for example, inserting a filter element 114, dosing the pod with beverage material 116, inserting a registration element 112, applying lidding material 110 and applying a pod bond 106, etc. It should be obvious to one skilled in the art that the aforementioned steps can be completed in any order, or completed partially before one step and completed after another step, or any such arrangement of steps in order to produce an assembled beverage pod.
