Pad For Preparing a Beverage

Abstract

A pad for preparing a beverage comprising: an upper part comprising a rigid or semi-rigid upper element containing one or more apertures forming an inlet of the pad; a flexible lower element depending from the upper part and formed at least partially from filtering material, the filtering material forming an outlet of the pad; the upper part and lower element together defining a storage volume containing a water-soluble composition or a combination or mixture of water-soluble compositions for forming a beverage, wherein the upper part comprises a flexible water-impermeable layer joined to the rigid or semi-rigid upper element.

Description

This application is a U.S. national phase application filed under 35 U.S.C. §371 of International application PCT/GB2005/004106, filed on Oct. 24, 2005, designating the United States, which claims the benefit of Great Britain patent application No. 0423542.0, filed on Oct. 22, 2004, which is hereby incorporated by reference herein.

The present invention relates to improvements in pads for preparing beverages which contain a water soluble substance. The water soluble substance may be a powdered ingredient for making a beverage such as coffee, tea or soup, fruit juice and desserts. The invention finds particular advantage where the water soluble substance is a milk powder or creamer powder. The pads are also known as pods, cartridges, capsules, pouches and bags.

It is known to provide flexible pads for use with beverage preparation machines which contain a water soluble substance such as a creamer powder. An example of a known pad is shown in FIGS. 1 and 2. The pad 10 is simple in construction and comprises a circular upper sheet 11 and a circular lower sheet 12 of filter material which are bonded together around a peripheral seam 15 to define and seal a storage volume 13 in which the water soluble substance 14 is contained. In use, the pad 10 is placed in a beverage preparation machine such as a coffee brewer and heated water is passed through the pad 10. The heated water flows through the upper sheet 11 and lower sheet 12 of filter material and in so doing contacts and dissolves the water soluble substance 14 contained in the storage volume 13 to form the beverage. The beverage then passes through the lower sheet 12 of the filter material and is dispensed into a suitable receptacle. The water soluble substance may be used to form the whole or part of a beverage. Where the water soluble substance is a milk powder or creamer powder, the pad may be used to form a milk-based beverage or to form a milk-based portion of an alternative beverage such as coffee.

Pads with creamer powders or milk based products may be used in dispensing cappuccino-style beverages. Such pads may be used in the beverage preparation machine on their own to dispense a milky, creamy or frothy beverage portion onto an already dispensed beverage, such as coffee. Alternatively, the pad containing the creamer powder or milk-based substance may be used in the beverage preparation machine in combination with a pad containing a substance for producing another beverage portion as taught in EP0756844. For example, two pads may be used at the same time in the machine, one pad containing a creamer powder and one pad containing roast and ground coffee. In this way, a complete beverage may be dispensed in one operation cycle of the beverage preparation machine.

The pads described above are similar to well known tea bags which are used for infusing hot water with tea leaves. However, there are a number of particular problems in using such flexible pads in beverage preparation machines where the pads contain a water soluble product such as a milk powder or creamer powder as opposed to a product which is infused in water but is not itself dissolved, such as roast and ground coffee or tea leaves. One disadvantage is that as the water soluble substance 14 is dissolved by the water passing through the pad, the pad tends to collapse in on itself bringing the upper sheet 11 and lower sheet 12 of filter material into contact with one another. In addition, because the dissolution of the water soluble substance 14 is not necessarily uniform throughout the storage volume of the pad 10 during use this can lead to portions of the filter material collapsing before the whole or a substantially part of the water soluble substance 14 has been dissolved. Where the upper sheet 11 and the lower sheet 12 of filter material contact one another, there is formed a low resistance flow path for the heated water. As a result, as soon as the pad 10 starts to collapse, the heated water has a tendency to flow through the portions of the pad 10 where the upper sheet 11 and lower sheet 12 are in contact rather than flowing more uniformly through the entire storage volume of the pad 10. This problem is exacerbated where the pad is used in a beverage preparation machine together with another pad containing another beverage portion as described above. It is preferred in such one-step dispensing of a beverage that the pad containing the infusible substance such as roast and ground coffee is placed on top of the pad containing the water soluble product so as to ensure proper extraction of the infusible substance as taught in EP0756844. However, the additional weight of the pad containing the infusible substance increases the likelihood that the pad containing the water soluble substance will collapse during the dispense cycle. For these reasons, use of pads such as those shown in FIGS. 1 and 2 can lead to substantial portions of the water soluble substance 14 being left within the pad 10 after the beverage preparation machine has completed its dispense cycle. Experiments show that for commonly used creamer powders as much as 40 to 60% of the creamer powder remains in the pad at the end of the dispense cycle. (The actual amount left depends to some extent on the dissolution properties of the creamer powder. Typically, the rate of flow of water is such that the beverage is prepared in under one minute. It is known with some compositions to include filler agents such as lactose. This results in poorer dissolution of the composition and an increased amount remaining in the pad after use. In contrast, the dissolution properties can be improved by use of agents such as surfactants. However, use of such agents has been found to result in only limited reduction in the amount of the substance left in the pad after use). This disadvantage can lead to a beverage or beverage portion being dispensed which is weaker than intended and also leads to wastage of the water soluble substance 14. Weak beverages can also be dispensed where the ingredients or part of the ingredients are by-passed by part of the water flow during dispensation.

Attempts have been made to overcome this problem by providing a form-retaining stiffening body within the interior of the storage volume 13. EP1398279 discloses use of a form-providing stiffening body comprising a grid structure that itself comprises a compartmenting wall configuration that spans between the upper and lower sheets of the flexible pad. Whilst the form-providing stiffening body prevents collapse of the pad and contact of the upper sheet and lower sheet of filter material, the structure described is complex and increases the cost and complexity of manufacture compared to the simpler pad as shown in FIGS. 1 and 2. In addition, the compartmenting wall configuration of the pad necessitates more careful filling of the storage volume with the water soluble substance to ensure consistent filling of the compartments.

Another disadvantage with the simple flexible pads of FIGS. 1 and 2 and the pad of EP1398279 is that, after use, the pad is left in a very wet state which is unpleasant for a user to handle when removing the pad manually from the beverage preparation machine. This can lead to dripping and soiling of the machine and surroundings as the pad is transported to a waste receptacle.

A further disadvantage of the known pads and the pads of EP1398279 is that, because substantial quantities of the water soluble substance can typically be left within the pad even at the end of a dispense cycle, the pad-holding section of the beverage preparation machine is left in a soiled state which is contaminated with beverage. As a result, the machine must be cleaned before a next beverage can be hygienically dispensed. The cleaning either involves manually disassembling the beverage preparation machine and washing the parts or by running another dispense cycle with no pad within the pad holding section so as to flush the beverage preparation machine. Both of these methods involves extra time and inconvenience to the user.

It is an object of the present invention to provide a pad which helps to alleviate at least some of these disadvantages.

Accordingly, the present invention provides a pad for preparing a beverage comprising:

an upper part comprising a rigid or semi-rigid upper element containing one or more apertures forming an inlet of the pad;

a flexible lower element depending from the upper part and formed at least partially from filtering material, the filtering material forming an outlet of the pad;

the upper part and lower element together defining a storage volume containing a water-soluble composition or a combination or mixture of water-soluble compositions for forming a beverage,

wherein the upper part comprises a flexible water-impermeable layer joined to the rigid or semi-rigid upper element.

Preferably the rigid or semi-rigid upper element is centrally located with the flexible water-impermeable layer surrounding the upper element.

An advantage of the pad of the present invention is that the rigid or semi-rigid upper element provides the pad, and specifically the inlet, with sufficient rigidity to make inflow of water into the pad easier and more controllable whilst still achieving some of the advantages of a flexible pad. In particular, the rigid or semi-rigid nature of the upper element ensures that the spatial relationship of the inlet apertures are is substantially maintained during use of the pad whilst the semi-flexible nature of the pad as a whole allows the pad to mould itself to the shape of a pad holder of a beverage preparation machine resulting in an improved fit and less chance of water by-pass in use. The pad is also easier to handle after use.

The lower element may be bonded to the upper part.

Preferably, the lower element depends from the upper element. The upper part may comprise a flexible water-impermeable layer, made from a material such as a foilized laminate, joined to the rigid or semi-rigid upper element.

Preferably, the lower element depends from the flexible water-impermeable layer.

Preferably, the lower element is bonded to the upper element.

Preferably the filtering material is filter paper. Alternatively, the filtering material is a flexible material comprising a plurality of finely-sized apertures. An example is a wire mesh. A further alternative is that the filtering material comprises a spongiform element. A further alternative is that the filtering material comprises a foamed plastic material. Preferably, the lower element is wholly or substantially wholly formed from filter paper.

Alternatively, the lower element may be formed at least in part from a perforated thin sheet water-impermeable material such as a foilized material or other flexible material. The material may comprise a single sheet or be a laminate of one or more materials. Suitable foilized materials for a portion of the upper part and the lower element include a laminate comprising two or more layers. In one example the laminate (known as duplex) comprises a 60 to 100 micron layer of PE and a 7 to 12 micron layer of metallised PET. Another example comprises a laminate (known as triplex) of a 50 to 100 micron layer of PE, a 7 to 9 micron layer of Aluminium and a 12 to 20 micron layer of PET. Both laminates are available from Alcon under the trade name AMOR. A quadruplex laminate may be formed by the addition a metallised PET layer to the triplex laminate.

The inlet apertures may be located at or near a centre of the upper part. Alternatively, the inlet apertures are located at or near a periphery of the pad.

The inlet apertures may be located in at least two discrete regions of the upper part. For example, a portion of the inlet apertures may be located at or near a centre of the upper part and a portion of the inlet apertures may be located at or near a periphery of the upper part.

The inlet apertures may be arranged in a circle. Alternatively, the inlet apertures may be distributed in a random or ordered configuration across the upper part. The inlet apertures may be circular in shape or in the form of square apertures or slits or other geometric shapes.

Preferably, the inlet of the pad is recessed below a remainder of the upper element. The upper element may comprise one or more cylindrical or frusto-conical recesses and the inlet apertures are formed at or near a base of said recesses. Recessing the inlet of the pad below the remainder of the upper surface allows the inlet apertures to be positioned within the bulk of the water soluble composition. As a result, the flow and jetting of the water through the inlet apertures into the storage volume takes place within the centre of the water soluble composition resulting in turbulence, better mixing, and improved dissolution of the composition. In addition, recessing the inlet apertures below the remainder of the upper element helps to prevent the apertures being blocked in the eventuality that an object that rests in use on the upper surface of the pad. For example, it may be desired to use the pad in combination with a pad containing roast and ground coffee in a one step beverage dispense cycle as described above. In this case the pad, which would typically be a flexible pad similar to that shown in FIGS. 1 and 2, would rest on the upper surface of the pad. Any sagging or distortion of the flexible pad during dispensing would not result in the inlet apertures of the pad being blocked as the recess would maintain a physical separation of the pad and the apertures.

In another embodiment the inlets are raised above the remainder of the upper element. Water flows into the inlets above the level of the upper element, with the uppermost part of the raised element providing a support for an upper pad. Thus providing an easy path into the inlets for either water, an infusion, dissolved substance or mixture thereof from an upper pad. This arrangement of inlets allows a uniform distribution of inlets across the pad surface so as to produce a uniform distribution of water through the lower pad.

In another embodiment the inlets are within the upper element and do not protrude beyond the lower surface of the upper element. The inlet size may be adjusted to maximise jetting within the pad.

In another embodiment the pad is inverted with the upper element blow the lower portion of the pad and is used with water flowing upwardly through the pad. This provides benefits for the solution of some substances since the flexible element is kept clear from the rigid or semi-rigid element.

The inlet may comprise 1 to 20 apertures.

At least some of the apertures may be directed radially outwards. At least some of the apertures may be directed radially inwards. At least some of the apertures may be directed tangentially relative to the recess. At least some of the apertures may be directed parallel to the upper element. At least some of the apertures may be directed upwards towards the upper element. At least some of the apertures may be directed downwards away from the upper element. Suitable angling of the apertures of the inlet can improve the circulation of the water within the storage volume during use and hence the dissolution of the water soluble composition. In particular, angling the apertures upwards towards the upper element, radially and downwardly ensures that the water reaches all parts of the storage volume. All of the apertures of the inlet may be similarly angled. Alternatively the apertures may have a combination of angles such that some are directed upwards, some radially, some tangentially and some downwardly. It will be clear that various combinations both regular and random can be achieved to produce differing flow patterns within the storage volume.

In other embodiments any of the aforementioned embodiments may be inverted with the water flowing upwardly through the pad. In a further embodiment with upward flow the semi-rigid or rigid element may be above or below the flexible bag. The upward flow through the bag floats the flexible bag or rigid or semi-rigid element and maintains a uniform water distribution throughout the flexible pad as the pad does not collapse.

Preferably, the apertures have an equivalent diameter of 0.1 mm to 5.0 mm. More preferably the apertures have an equivalent diameter of 0.3 mm to 0.7 mm.

The pad may be circular with a diameter of between 30 and 110 mm. Preferred diameters are between 60 and 70 mm, between 30 and 40 mm and between 100 and 110 mm. The diameter of the pad will depend on the nature of the beverage preparation machine for use with the pads.

Preferably the storage volume further contains a dispersion plate for creating a non-vertical flow of water, in use, within the storage volume and increasing the superficial velocity of the water in the pad.

The dispersion plate may be freely suspended within the storage volume. Alternatively the dispersion plate is attached to the filtering material. Alternatively the dispersion plate is formed in the plane of the filtering material. Alternatively the dispersion plate could be fixed to the upper element. The dispersion plate may form part of an outlet filtering means.

The dispersion plate may comprise a portion of the outlet filtering means which has modified material characteristics and is non-transmissive to water.

The outlet filtering means may comprise a filter paper and the dispersion plate comprises a portion of the filter paper which is hot stamped to render it impermeable to water.

More than one dispersion plate may be utilised in the pad.

The pad may further comprise a dispersion plate attached to an outer surface of the pad.

The pad may comprise more than one dispersion plate.

The dispersion plate may be planar. Alternatively, the dispersion plate may be rippled, ridged or otherwise convoluted.

The dispersion plate may be non-apertured or may comprise one or more apertures. The dispersion disc may be sealed or bonded to the lower surface and the one or more apertures may be formed at the boundary between the dispersion disc and the outlet filtering means.

The dispersion plate may form part of an outlet filtering means. The dispersion disc may comprise a portion of the outlet filtering means which has modified material characteristics and is non-transmissive to water. For example, the outlet filtering means may comprise a filter paper and the dispersion disc may comprise a portion of the filter paper which is hot stamped to render it impermeable to water.

The storage volume may further contain one or more absorbent elements or particles.

The absorbent elements or particles may be spongiform. For example, compressed sponge or natural sponge. Dried seaweed can form a suitable alternative material. The sponge is stable and is of food grade quality which is suitable for storing in contact with beverage ingredients. Compressed sponge exhibits good expansion behaviour in contact with water and has good water absorbency in the expanded state.

The absorbent elements or particles may be a hydrogel or other material which swells in water. Suitable hydrogels include poly (HEMA) 2 hyroxyethyl methacrylate, polyacrylic, polyacyrylamide, Gelatine, Alginates, Agar and Carrageenan, and other hydrocolloids.

In one example the absorbent particles have a particle size of between 0.1 and 10 mm. This is particularly where the particle are formed from a spongiform material. The absorbent particles may have a particle size of about 3 mm.

In another example the absorbent particles have a particle size of between 25 to 100 microns. This is particularly where the particles are formed from an hydrogel.

Before exposure to liquid, the one or more absorbent elements or particles may be compressed.

Preferably, the expansion in the absorbent particles is between 25 and 1000%, preferably 100 to 500%. The expansion may be omni-directional, bi-directional or uni-directional.

In use, the one or more spongiform elements or absorbent particles may act as an absorbent means for retaining excess moisture. The water retaining properties of the spongiform or hydrogel particles or elements help to retain the majority of any excess water that is left within the pad after the end of the dispense cycle. As a result the user may pick up the used pad and remove it to a waste receptacle with less soiling or dripping. In addition, the water absorbency of the spongiform or hydrogel particles or elements means that less liquid is left in the pad holding section of the beverage preparation machine. As a consequence, cleaning of the machine is made easier.

The pad may contain a single spongiform or hydrogel element.

The one or more absorbent particles may interact with water in use such as to absorb water only during a portion of a dispense cycle. For example the one or more absorbent particles may interact with water at a predetermined temperature, pH or a start of a specified chemical reaction.

In one example the one or more absorbent particles comprise a soluble coating which, in use, is dissolvable in water to allow absorption of water to take place. The soluble coating may comprise sugar or gelatine.

The pad may contain one or more foamed plastic elements or particles. The foamed plastic element may be formed with air or other gases. The foamed plastic may absorb water or may contain closed cells so the material does not substantially absorb water.

Preferably, the water-soluble composition is agglomerated. The agglomerated water-soluble composition may be produced by contacting the water-soluble composition with steam, water, or aqueous solution or dispersion to effect agglomeration, and optionally, either simultaneously or subsequently drying the agglomerated composition. In a comparison test, the amount of powder residue left in a standard pad was reduced from 50% to 35% when using an agglomerated powder rather than a non-agglomerated powder.

For the purposes of the present invention, water-soluble substances or compositions are defined as substances which wholly or substantially dissolve in the presence of a solvent which will typically be water. The ingredient composition of the substance before and after dissolution is substantially the same (excluding the diluting effect of the solvent). Thus, water-soluble substances exclude infusible substances such as roast and ground coffee and leaf tea. With infusible substances the ingredient composition of the infusion is substantially different to the ingredient composition of the infusible or extractable precursor since the infusion only contains certain flavour and/or aromatic qualities of the infusible substance. Examples of water-soluble substances according to the present invention include compositions such as milk powder, creamer powder, instant whitener, instant coffee, instant tea, instant soup, instant chocolate drink, sugar, instant fruit juice and instant dessert powders.

Preferably, the water-soluble composition is a milk powder, creamer or chocolate powder. The milk powder or creamer powder may be a dairy or non-dairy spray-dried coffee creamer or coffee whitener. The fat component of the milk powder or creamer powder may have a melting point of 10 to 40 degrees Celsius. The creamer powder may comprise one or more of vegetable fat, milk proteins, emulsifiers, stabilisers, foaming agents, milk fat, soy proteins, modified starches, carriers, fillers, sweeteners, flavours, colours, nutrients, preservatives and flow agents.

In one embodiment the pad further comprises one or more channels or grooves in the upper surface, said channels or grooves extending towards the inlet. Preferably, the channels or grooves cover the upper surface and extend from the edge to the centre. Where the pad is used with upward flow of water the grooves or channels may be provided in the lower surface of the pad. The channels may have a depth of 0.1 to 5 mm, preferably 1 to 2 mm and a width of 1 to 3 mm. Preferably, the channels and grooves extend radially towards a central inlet, or where there the apertures of the inlet are in more than one location towards the apertures. The channels or grooves assist in flow of water to the inlet of the pad is use. This is particularly advantageous when the pad is used in a one step procedure where a flexible pad is placed on top of the pad or a flexible pad is placed under the pad where upward flow of water is used. The grooves or channels ensure that the water can pass through extractable material that may be placed above the pad, thus significantly improving extraction efficiency. Additionally, the grooves or channels ensure that the water can pass into the inlet of the pad without becoming blocked by sagging or distortion of the filtering material of the flexible pad. Rather than channels or grooves, vertical struts, pyramid structures or similar may be used to raise the filtering material of a pad off the upper element.

The present invention also provides a beverage brewing kit comprising a first pad as described above in combination with a second pad containing one or more beverage ingredients suitable for brewing.

Preferably the second pad contains roast and ground coffee. Preferably the first and second pads are joined prior to use.

The present invention further provides a method of dispensing a beverage using a pad as described above comprising the step of passing water downwardly through the pad such that beverage initially exits the pad through a lowermost surface thereof.

Alternatively water may pass upwardly through the pad such that beverage initially exits the pad through an uppermost surface thereof.

Alternatively the pad may be orientated in a non-horizontal orientation, such as a vertical orientation, and water passed in a vertical or non-vertical direction through the pad.

Flow of water through the pad may be substantially parallel to a major axis of the pad or substantially cross-ways to a major axis of the pad or in a direction part-way between parallel flow and cross flow.

Preferably water is passed through the flexible pad at a temperature greater than 70 degrees Celsius.

Optionally water is passed through the flexible pad as a discontinuous flow. Optionally, water is in the form of a pulsed flow.

A beverage is prepared using the pads of the present invention by inserting the pads in a beverage preparation machine. The pads may be used in a variety of beverage preparation machines. In one example, the beverage preparation machine generally comprises a housing containing a water heater, a water pump, optionally an air compressor, a control processor, a user interface and a head. The head in turn generally comprises a holder for holding, in use, the pad. The beverage preparation machine is also provided with a water tank.

The housing comprises a dispense station where dispensation of the beverage takes place. The dispense station comprises a receptacle stand having a hollow interior forming a drip tray.

The head is located towards the top of the housing above the receptacle stand. The holder of the head is shaped to receive the pad of the present invention and to hold the pad in the correct orientation such that water may be passed through the pad. Preferably the holder and head are provided with sealing means for sealing around a periphery of the pad to prevent by-pass flow of water in use. The head may be designed to direct flow of water downwardly through the pad so that beverage exits the pad through a lowermost surface of the pad. Alternatively, the head may be designed to direct flow of water upwardly through the pad so that beverage initially exits the pad through an uppermost surface of the pad before being ultimately directed downwardly to a receptacle. Of course the pad may be used in an orientation other than horizontal, for example, in a vertical orientation.

The user interface is located on the front of the housing and comprises a start/stop button, and a plurality of status indicators.

The start/stop button controls commencement of the operating cycle and is a manually operated push-button, switch or similar.

The water tank is located to the rear of the housing and is connected in use to a water tank station located at a rear half of the housing.

The water pump is operatively connected between the water tank and the water heater and is controlled by the control processor.

The water heater is located in the interior of the housing. The heater is able to heat water received from the water pump from a starting temperature of approximately 20° C. to an operating temperature of around 85° C. in under 1 minute.

The control processor of the beverage preparation machine comprises a processing module and a memory. The control processor is operatively connected to, and controls operation of, the water heater, water pump, air compressor and user interface.

Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings in which:

FIG. 1 is an upper plan view of a prior art flexible pad;

FIG. 2 is a cross-sectional view of the flexible pad of FIG. 1;

FIG. 3 is a cross-sectional view of a first embodiment of pad according to the present invention before use;

FIG. 4 is a cross-sectional view of the pad of FIG. 3 after use;

FIG. 5 is a cross-sectional view of a second embodiment of pad according to the present invention;

FIG. 6 is a cross-sectional view of a third embodiment of pad according to the present invention; and

FIG. 7 is a cross-sectional view of a fourth embodiment of pad according to the present invention.

FIGS. 3 and 4 illustrate a first embodiment of pad 10 according to the present invention. The pad comprises a rigid or semi-rigid upper element 20 having a planar upper surface 27 with a centrally located recess 24. The base of the recess 24 is provided with six apertures 25. The recess 24 is frusto-conical and the apertures 25 are located at the base of the recess 24.

A sheet of filtering material 12 in the form of filter paper is bonded by means of a peripheral seal 15 to the upper element 20. A storage volume 31 is defined between the upper element 20 and lower sheet 12.

The filtering material can be bonded by heat or adhesive.

The pad may be circular with a diameter of between 30 and 110 mm. Preferred diameters are between 60 and 70 mm, between 30 and 40 mm and between 100 and 110 mm.

The storage volume 31 contains a volume of a water soluble composition 14. The invention finds particular application where the water soluble substance 14 is a milk powder or creamer powder. Milk powders include dried skimmed milk, part-skimmed milk, and whole milk, dried milk protein concentrates, isolates, and fractions, or any combination thereof. Creamer powders can be manufactured from dairy and/or non-dairy food ingredients and typically contain emulsified fat, stabilized by protein or modified starch, dispersed in a carrier that facilitates drying, especially spray drying. Optional ingredients include buffers, flavours, colours, fillers, sweeteners, foaming agents, flow agents, nutrients, preservatives, and the like. Milk powders and creamer powders are particularly useful as coffee whiteners for brewed, soluble, and flavoured coffee products, including latte and cappuccino. In the following description, for example only, the water soluble substance will be described as a creamer powder unless the context otherwise requires.

The creamer powder may for example comprise the following by weight:

Hardened vegetable fat           49%
Glucose syrup                    41%
Sodium Caseinate                 4.5%
Polyphosphates - K2HPO4          2.0%
Na-Polyphosphate                 2.5%
Silicon dioxide                  0.25%
Emulsifier (Sodium stearoyl-2-lactylate) 0.75%

Other compositions may be used which contain fillers such as lactose and additional stabilisers. Additional emulsifiers may be added to improve wetting. Advantageously, the creamer may be provided in an agglomerated form to assist and improve solubility. Advantageously, the creamer powder may comprise a low melting temperature fat having a melting temperature of between 10 and 40 degrees Celsius. Some or all of the fat content of the composition noted above may be substituted for low melting temperature fat. In one example the composition comprises 24% low melting temperature fat and 25% fat with a melting temperature of above 40 degrees Celsius. This results in a reduction of creamer powder residue in the pad of around 15 to 20%.

The storage volume 31 is also provided with a dispersion disc 30 which is freely moveable within the storage volume 31. As shown in FIG. 3, the dispersion disc 30 is located towards the bottom of the storage volume 31 in contact with the filtering material 12. However, the dispersion disc 30 may be located within the bulk of the creamer powder or on top of the creamer powder. Indeed, in use, the dispersion disc 30 will tend to move somewhat within the interior of the storage volume 31.

The upper element 20 and dispersion disc 30 are formed from a rigid or semi-rigid material such as polypropylene, polyester, polystyrene, polyurethane, nylon, other engineering plastics, composites, metal, metal-plastic composites, card, wood, rubber or biodegradable plastics such as degradable polyethylene (for example, SPITEK supplied by Symphony Environmental, Borehamwood, United Kingdom), biodegradable polyester amide (for example, BAK 1095 supplied by Symphony Environmental), poly lactic acids (PLA supplied by Cargil, Minn., USA), starch-based polymers, cellulose derivatives and polypeptides. The material may be thermoformed, compression moulded or injection moulded.

In use, the pad 10 is placed in a suitable beverage preparation machine and water is passed through the pad 10. The water enters the storage volume 31 through the inlet apertures 25 at the base of the recess 24. In the embodiment shown, the apertures 25 are angled so as to direct jets of water radially towards the side of the pad 10. The water circulates within the unitary storage volume 31 of the pad 10 dissolving the creamer powder to form the beverage. The beverage is then able to pass through the layer of filtering material 12 at a lower surface of the pad 10 and out of the beverage preparation machine. The dispersion disc 30 prevents water flowing directly through the storage volume 31 but instead diverts the water to circulate within the volume.

After use, the user of the beverage preparation machine may remove the pad 10 and dispose of it in a waste receptacle. Advantageously, the rigidity of the pad 10 imparted by the rigid or semi-rigid upper element 20 makes for easier handling of the pad 10 compared to the prior art pad of FIGS. 1 and 2. In addition the rigidity ensures that the inlet apertures 25 are kept open and of a known size.

With the pad 10 of FIGS. 3 and 4 the amount of creamer residue remaining within the storage volume 31 was reduced to less than 20%.

A second embodiment is shown in FIG. 5. This embodiment differs in that the dispersion disc 30 is bonded to the sheet 12 of filter paper and is not free to move within the storage volume 31. The disc 30 may be bonded to the inner or outer surface of the filter sheet 12.

A third embodiment is shown in FIG. 6. This embodiment differs in that the rigid or semi-rigid upper element 20′ does not extend across the whole of the upper surface of the pad 10. Rather the rigid or semi-rigid element 20′ is smaller and is bonded to a layer of impermeable but flexible material 11 that forms the remainder of the upper surface of the pad 10′. The flexible material 11 may be a foil, plastic or other laminated material. The pad 10 may or may not include a dispersion disc as described above. Use of a flexible material in the upper surface of the pad allows the pad to adapt more easily to the shape of a pad holder in a beverage preparation machine in use.

In the above three embodiments the structure of the recess 24 helps to prevent collapse of the pad 10 during use as it acts as a spacer that holds the central regions of the upper element 20 and the lower filter material 11 apart. This aids dissolution of the creamer powder.

A fourth embodiment is shown in FIG. 7 which is similar in structure to the embodiment of FIG. 6. The structure differs in that a three rigid or semi-rigid fins 35 are provided within the storage volume 31. The fins 31 do not extend all the way across the storage volume 31 and hence do not compartmentalise the storage volume. Instead the fins 35 act as a support for holding the upper layer of flexible material 11 and the lower layer of filtering material 12 apart during use. More than three fins 35 may be provided if desired.

In a non-illustrated embodiment, the storage volume 31 also contains a spongiform element in the form of a circular disc of compressed sponge material. The disc has preferred diameters of 100 to 100 mm, 50 to 59 mm and 30 to 40 mm and a thickness of 3 mm. The disc is formed from cellulose sponge such as that manufactured by 3M. Other suitable materials for the spongiform element include other food grade materials with similar physical properties to those of cellulose sponge in terms of there porosity and or expandability.

Prior to use of the pad, the pad and its contents are dry. If necessary, the pad can be supplied in an hermetically sealed package to prevent moisture ingress or absorption.

The compressed sponge disc may be positioned on top of the creamer powder within the storage chamber 31. Alternatively, the compressed sponge may be positioned underneath the creamer powder or within the mass of the creamer powder.

In use, the pad is used as described above. On contact with the water, the compressed sponge rapidly expands. In the expanded state the disc has a thickness of between 10 and 20 mm, preferably around 15 mm. Thus, the action of the liquid on the compressed sponge is to produce an expansion in the thickness of the compressed sponge of around 500%. The compressed sponge may be configured to expand generally only in one dimension, i.e. its thickness, or may be configured to expand three-dimensionally, i.e. to increase it's thickness and also it's diameter. Water is able to pass through the expanded compressed sponge substantially unhindered. As a result, the water quickly contacts and dissolves the creamer powder to produce the milk based beverage or beverage portion. The beverage containing the dissolved creamer powder passes through the lower filter layer 22 and out of the beverage preparation machine.

Advantageously, the porous water-retaining nature of the spongiform element helps to retain excess moisture that may be within the pad. The capillary action of the pores of the spongiform element help to prevent dripping from the pad as it is transferred to a waste receptacle. In addition, the water-retaining nature of the spongiform element has the consequence that the pad holding section of the beverage preparation machine contains less moisture and hence less contamination than compared with the use of prior art pads. As a result the machine is easier to clean and prepare in readiness for the next dispense cycle. In the above the pad has been described as containing spherical spongiform particles. However, the particles may take other forms such as block shapes, irregular shapes or be formed as shredded portions of a sheet material.

In an alternative, non-illustrated embodiment, the storage volume 31 also contains a plurality of absorbent particles in the form compressed sponge material. The particles 20 each a size (diameter or length) of 1 to 10 mm and a thickness of 1 to 3 mm before use. The particles 20 are formed from compressed cellulose sponge. Preferably the ratio by weight of the creamer powder to the absorbent particles before use is from 20:1 to 2:1, preferably around 3:1.

The compressed particles are dispersed throughout the creamer powder within the storage chamber.

In use, the pad is used as described above. On contact with the water, the compressed particles rapidly expand. In the expanded state the particles have a thickness of around 15 mm. The diameter of the particles is not substantially changed, i.e. the expansion is uni-directional. Thus, the action of the liquid on the compressed sponge is to produce an expansion in the compressed sponge of around 500%. Water is able to pass through the expanded sponge substantially unhindered. As a result, the water quickly contacts and dissolves the creamer powder to produce the milk based beverage or beverage portion. The beverage containing the dissolved creamer powder passes through the filter material 22 and out of the beverage preparation machine.

Advantageously, the porous water-retaining nature of the spongiform particles helps to retain excess moisture that may be within the pad. The capillary action of the pores of the spongiform particles help to prevent dripping from the pad as it is transferred to a waste receptacle. In addition, the water-retaining nature of the spongiform particles has the consequence that the pad holding section of the beverage preparation machine contains less moisture and hence less contamination than compared with the use of prior art pads. As a result the machine is easier to clean and prepare in readiness for the next dispense cycle.

In another, non-illustrated, embodiment, the spongiform particles are replaced by particles of a hydrogel substance in the form of spherical or otherwise shaped particles. In use, and on contact with water, the hydrogel absorbs water and expands. The expansion of the hydrogel particles aids dissolution of the creamer powder. Advantageously, the intake of water by the hydrogel is rapid and results in the hydrogels absorbing preferentially water rather than dissolved creamer powder.

The pads may advantageously comprise grooves or channels on the upper surface of the upper element 20 to aid inflow of water towards the inlet apertures 25. The grooves or channels are preferably linear and, in the case of a central inlet recess 24, radially inwardly directed towards the recess 24. The grooves or channels are preferably 1 to 2 mm in depth so as to prevent blockage when the pad is used together with a flexible pad in a one step dispense cycle.

In a non-illustrated embodiment the absorbent particles are separated from the water-soluble composition by means of a layer of material, such as filter material. In this way the storage volume 13 can be divided either into horizontal layers or vertical compartments.

In the above the pad has been described as containing absorbent particles. The particles 20 may take various forms such as spheres, block shapes, tubes, rods, irregular shapes or be formed as shredded portions of a sheet material.

The flexible pad of the present invention may be provided with one or more structural supports in addition to the absorbent particles which span between opposed faces of the pad.

The water soluble substance has been described as preferably being a milk- or dairy-based creamer powder. However the pads of the present invention may also find application with other soluble ingredients such as instant coffee, instant tea, chocolate, soup or dessert ingredients.

The lower sheet 12 have been described as being formed from filter material, such as that used commonly to form tea bags. However, other suitable materials may be used which are non-transmissive to the water soluble substance in the dry form but are transmissive to the water soluble substance when dissolved in water. For example, in an alternative embodiment the lower sheet may be formed from a foilized or spongiform material such as compressed sponge or expanded sponge. The sponge has a pore size that prevents transmission of the powdered form of the water-soluble composition but allows the dissolved composition to pass.

In another pad, the powdered composition of the pad may be held in a mass of spongiform material of the types described above with no void space forming a separate storage volume. Rather, the powdered composition is dispersed within the dry sponge pore matrix and held within the spongiform material until water is passed through the pad at which point the powdered composition is dissolved and passes out of the sponge. Preferably the pore size of the dry sponge is 1 to 100 microns, more preferably 10 to 50 microns.

The pads of the present invention may also comprise one or more seals to allow for improved engagement of the pad with a pad holder of the beverage preparation machine. A seal or seals may be provided on or adjacent the upper element. The seal help to prevent water by-pass by reducing or eliminating the quantity of water that does not pass through the inlet apertures.

In the above description, the storage chamber 13 has been described as a unitary volume. However, the volume may be separated into multiple compartments using flexible materials. The chambers may if desired contain different beverage ingredients or the same ingredients. Some or all of the compartments may comprise absorbent bodies of the types described above. Some or all of the compartments may have dispersion discs contained therein.

Whilst the pad has been particularly described with an inlet at the centre of the upper element other arrangements are within the scope of the present invention. In particular the inlet recess may be formed near the periphery of the upper element. Further, the upper element may comprise more than one recess, each having apertures such that the inlet to the pad is distributed in at least two discrete regions of the upper element. For example, three recesses of the form of recess 24 of FIG. 3 may be provided.

The pad may be used for dispensing hot and cold beverages. Still and carbonated beverages may be produced by using still or carbonated water. The absorbent particles may be formed from a hydrogel, starch or a mixture of one or more of spongiform, starch and hydrogel materials.

Claims

1. A pad for preparing a beverage comprising:

an upper part comprising a rigid or semi-rigid upper element containing one or more apertures forming an inlet of the pad;

a flexible lower element depending from the upper part and formed at least partially from filtering material, the filtering material forming an outlet of the pad;

the upper part and lower element together defining a storage volume containing a water-soluble composition or a combination or mixture of water-soluble compositions for forming a beverage;

wherein the upper part comprises a flexible water-impermeable layer joined to the rigid or semi-rigid upper element.

2. A pad as claimed in claim 1 wherein the rigid or semi-rigid upper element is centrally located with the flexible water-impermeable layer surrounding the upper element.

3. A pad as claimed claim 2 wherein the lower element is bonded to the upper part.

4. A pad as claimed in claim 3 wherein the lower element depends from the flexible water-impermeable layer.

5. A pad as claimed in claim 4 wherein the filtering material is filter paper.

6. A pad as claimed in claim 5 wherein the lower element is wholly or substantially wholly formed from filter paper.

7. A pad as claimed in claim 1 wherein the filtering material comprises a spongiform material.

8. A pad as claimed in claim 1 wherein the filtering material comprises a foamed plastic material.

9. A pad as claimed in claim 1 wherein the filtering material comprises a perforated thin sheet water-impermeable material.

10. A pad as claimed in claim 9 wherein the thin sheet water-impermeable material is a foilized material.

11. A pad as claimed in claim 9 wherein the thin sheet water-impermeable material comprises one or more apertures forming the outlet of the pad.

12. A pad as claimed in claim 11 wherein the apertures in the thin sheet water-impermeable material are covered by filter paper.

13. A pad as claimed in claim 1 wherein the inlet apertures are located at or near a centre of the upper part.

14. A pad as claimed in claim 1 wherein the inlet apertures are located at or near a periphery of the pad.

15. A pad as claimed in claim 1 wherein the inlet apertures are located in at least two discrete regions of the upper part.

16. A pad as claimed in claim 15 wherein a portion of the inlet apertures are located at or near a centre of the upper part and a portion of the inlet apertures are located at or near a periphery of the upper part.

17. A pad as claimed in claim 16 wherein the inlet apertures are arranged in a circle.

18. A pad as claimed in claim 16 wherein the inlet apertures are distributed across the upper element.

19. A pad as claimed in claim 18 wherein the inlet apertures are circular in shape or in the form of square apertures or slits or other geometric shapes.

20. A pad as claimed in claim 19 wherein the inlet of the pad is recessed below a remainder of the upper part.

21. A pad as claimed in claim 20 wherein the upper element comprises one or more cylindrical or frusto-conical recesses and the inlet apertures are formed at or near a base of said recesses.

22. A pad as claimed in claim 21 wherein the inlet comprises 1 to 20 apertures.

23. A pad as claimed in claim 22 wherein at least some of the apertures are directed radially outwards.

24. A pad as claimed in claim 22 wherein at least some of the apertures are directed radially inwards.

25. A pad as claimed in claim 22 wherein at least some of the apertures are directed tangentially relative to the recess.

26. A pad as claimed in claim 22 wherein at least some of the apertures are directed parallel to the upper element.

27. A pad as claimed in claim 22 wherein at least some of the apertures are directed upwards towards the upper element.

28. A pad as claimed in claim 22 wherein at least some of the apertures are directed downwards away from the upper element.

29. A pad as claimed in claim 22 wherein the apertures have an equivalent diameter of 0.1 mm to 5.0 mm.

30. A pad as claimed in claim 29 wherein the apertures have an equivalent diameter of 0.3 mm to 0.7 mm.

31. A pad as claimed in claim 1 wherein the storage volume further contains a dispersion plate for creating a non-vertical flow of water, in use, within the storage volume.

32. A pad as claimed in claim 31 wherein the dispersion plate is freely suspended within the storage volume.

33. A pad as claimed in claim 31 wherein the dispersion plate is attached to the filtering material.

34. A pad as claimed in claim 31 wherein the dispersion plate is formed in the plane of the filtering material.

35. A pad as claimed in claim 31 wherein the dispersion plate forms part of the lower surface.

36. A pad as claimed in claim 31 wherein the dispersion plate is planar.

37. A pad as claimed in claim 31 wherein the dispersion plate is rippled, ridged or otherwise convoluted.

38. A pad as claimed in claim 31 wherein the dispersion plate is non-apertured.

39. A pad as claimed in claim 31 wherein the dispersion plate comprises one or more apertures.

40. A pad as claimed in claim 31 wherein the dispersion plate forms part of an outlet filtering means.

41. A pad as claimed in claim 40 wherein the dispersion plate comprises a portion of the outlet filtering means which has modified material characteristics and is non-transmissive to water.

42. A pad as claimed in claim 41 wherein the outlet filtering means comprises a filter paper and the dispersion plate comprises a portion of the filter paper which is hot stamped to render it impermeable to water.

43. A pad as claimed in claim 1 further comprising a dispersion plate attached to an outer surface of the pad.

44. A pad as claimed in claim 43 comprising more than one dispersion plate.

45. A pad as claimed in claim 1 wherein the storage volume further contains one or more absorbent elements or particles.

46. A pad as claimed in claim 45 wherein the absorbent elements or particles are spongiform.

47. A pad as claimed in claim 45 wherein the absorbent elements or particles are a hydrogel.

48. A pad as claimed in claim 45 wherein, before exposure to liquid, the one or more absorbent elements or particles are compressed.

49. A pad as claimed in claim 46 wherein, in use, the one or more spongiform elements or absorbent particles act as an absorbent means for retaining excess moisture.

50. A pad as claimed in claim 45 containing a single spongiform or hydrogel element.

51. A pad as claimed in claim 45 wherein the one or more absorbent particles interact with water in use such as to absorb water only during a portion of a dispense cycle.

52. A pad as claimed in claim 51 wherein the one or more absorbent particles interact with water at a predetermined temperature, pH or a start of a specified chemical reaction.

53. A pad as claimed in claim 52 wherein the one or more absorbent particles comprise a soluble coating which, in use, is dissolvable in water to allow absorption of water to take place.

54. A pad as claimed in claim 53 wherein the soluble coating comprises sugar or gelatine.

55. A pad as claimed in claim 1 containing one or more foamed plastic elements or particles.

56. A pad as claimed in claim 1 wherein the water-soluble composition is agglomerated.

57. A pad as claimed in claim 56 wherein the agglomerated water-soluble composition is produced by contacting the water-soluble composition with steam, water, or aqueous solution or dispersion to effect agglomeration, and optionally, either simultaneously or subsequently drying the agglomerated composition.

58. A pad as claimed in claim 57 wherein the water-soluble composition is a milk powder, creamer or chocolate powder.

59. A pad as claimed in claim 58 wherein the milk powder or creamer powder is a dairy or non-dairy spray-dried coffee creamer or coffee whitener.

60. A pad as claimed in claim 58 wherein a fat component of the milk powder or creamer powder has a melting point of 10 to 40 degrees Celsius.

61. A pad as claimed in claim 59 wherein the creamer powder comprises one or more of vegetable fat, milk proteins, emulsifiers, stabilisers, foaming agents, milk fat, soy proteins, modified starches, carriers, fillers, sweeteners, flavours, colours, nutrients, preservatives and flow agents.

62. A pad as claimed in claim 1 further comprising one or more channels or grooves in an upper surface of the upper element, said channels or grooves extending towards the inlet.

63. A pad as claimed in claim 62 wherein the channels have a depth of 0.1 to 5 mm.

64. A pad as claimed in claim 63 wherein the channels or grooves have a depth of about 1 to 2 mm.

65. A pad as claimed in claim 62 wherein the upper surface comprises vertical struts, pyramid structures or similar.

66. A beverage brewing kit comprising a first pad as claimed in claim 1 in combination with a second pad containing one or more beverage ingredients suitable for brewing.

67. A beverage brewing kit as claimed in claim 66 wherein the second pad contains roast and ground coffee.

68. A beverage brewing kit as claimed in claim 67 wherein the first and second pads are joined prior to use.

69. A method of dispensing a beverage using a pad as claimed in claim 1 comprising the step of passing water downwardly through the pad such that beverage initially exits the pad through a lowermost surface thereof.

70. A method of dispensing a beverage using a pad as claimed in claim 1 comprising the step of passing water upwardly through the pad such that beverage initially exits the pad through an uppermost surface thereof.

71. A method of dispensing a beverage using a pad as claimed in claim 1 comprising the step of orientating the pad in a non-horizontal orientation and passing water in a vertical or non-vertical direction through the pad.

72. A method of dispensing a beverage using a pad as claimed in claim 1 comprising the step of passing a flow of water through the pad substantially parallel to a major axis of the pad or substantially cross-ways to a major axis of the pad or in a direction part-way between parallel flow and cross flow.

73. A method of dispensing a beverage using a flexible pad as claimed in claim 1 comprising the step of passing water through the flexible pad at a temperature greater than 70 degrees Celsius.

74. A method of dispensing a beverage using a flexible pad as claimed in claim 1 comprising the step of passing water through the flexible pad as a discontinuous flow.

75. A method of dispensing a beverage as claimed in claim 74 wherein the discontinuous flow of water is a pulsed flow.