BEVERAGE CARTRIDGE AND METHOD OF MANUFACTURE THEREOF
A beverage cartridge comprising an outer container, a sleeve, and a support device adapted for supporting a filter element. The sleeve comprises one or more protrusions extending towards the interior of the sleeve, and the support device comprises one or more recesses adapted for receiving the one or more protrusions. The outer container, the sleeve, and the support device are securely engaged. The outer container is made of a biodegradable and compostable fibre material such as, but not limited to, polylactic acid, bamboo, bagasse, or a combination thereof. At least a part of the sleeve and support device is made of a biodegradable and compostable material such as, but not limited to, polylactic acid, or a combination of biodegradable and compostable materials. Also disclosed is a method of manufacturing the beverage cartridge, and use of the support device in the manufacture of the beverage cartridge.
The present disclosure relates to a beverage cartridge such as, for example, a compostable beverage cartridge for single-serve use. The present disclosure further relates to methods of manufacture and uses thereof.
BACKGROUNDThe popularity of single-serve beverage cartridges has grown rapidly over the past decade, as more and more people trend towards the desire to brew or prepare beverages quickly and in single-portion quantities.
Beverage cartridges for single-serve use typically comprise a container, a filter, and a cover. The container will usually comprise an opening on the top of the container, and a hollow cavity within which and across which a filter is disposed. The filter separates the container into two chambers: a first chamber occupying the space within the container between the filter and the opening of the container, the first chamber for holding dry beverage ingredients such as, but not limited to, coffee, tea, or cocoa, for a single beverage serving; and (ii) a second chamber occupying the space within the container between the filter and the base of the container, the second chamber being on the opposite side of the filter to the first chamber. The cover is disposed over the opening of the container, and keeps the dry beverage ingredients within the container.
In practice, a single-serve beverage cartridge is placed into a compartment of a brewing machine. The machine is activated such that a fluid injector penetrates the cover of the cartridge and a fluid extractor penetrates the base of the cartridge. The fluid injector injects a brewing medium (e.g. hot water) into the first chamber for extracting flavours from the ingredients. The brewing medium containing the extracted flavours percolates through the filter and into the second chamber. The brewing medium containing the extracted flavours is then extracted by the fluid extractor and eventually dispensed as a drinkable beverage.
Currently, the container of a beverage cartridge for single-serve use is typically made from petroleum-based plastic materials which are neither biodegradable nor compostable. The cover is typically made of a metal foil or a metal foil laminate which is glued to the top of the container. Generally, neither the metal foil of the cover nor the glue affixing the cover over the opening of the container is biodegradable, compostable or made from readily renewable resources. As a result, non-biodegradable and non-compostable beverage cartridges typically end up in landfills, thereby at least contributing to environmental concerns associated with disposal of trash.
SUMMARYThe present disclosure relates to a beverage cartridge such as, for example, a compostable beverage cartridge for single-serve use. The present disclosure further relates to methods of manufacture and uses thereof.
At least in part, the present disclosure provides a device adapted for inserting into a beverage cartridge, the device comprising a first element, the first element comprising: (i) a first surface; (ii) a second surface that is substantially opposed to the first surface; (iii) a channel extending between the first surface and the second surface; and (iv) a third surface extending between the first surface and the second surface, the third surface comprising one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge.
At least in part, the present disclosure further provides a device adapted for inserting into a beverage cartridge, the device comprising a first element, the first element comprising: (i) a first surface; (ii) a second surface that is substantially opposed to the first surface; (iii) a channel extending between the first surface and the second surface; and (iv) a third surface extending between the first surface and the second surface, the third surface comprising one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge. The device further comprises a second element coupled to the first element and adapted for supporting a filter element, the second element comprising: (i) a first extension extending away from the first element and along a first axis; and (ii) a second extension extending away from the first element and along a second axis; wherein the first axis and the second axis intersect.
At least in part, the present disclosure further provides a device adapted for inserting into a beverage cartridge, the device comprising a first element, the first element comprising: (i) a first surface; (ii) a second surface that is substantially opposed to the first surface; (iii) a channel extending between the first surface and the second surface; and (iv) a third surface extending between the first surface and the second surface, the third surface comprising one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge. At least in part, the present disclosure. At least a part or all of the device is made of a compostable material.
At least in part, the present disclosure further provides a beverage cartridge, the cartridge comprising: (a) a sleeve comprising: (i) a perimetral ledge; (ii) an opening surrounded by the perimetral ledge; (iii) a base; (iv) a side wall extending between the base and the perimetral ledge; and (v) one or more protrusions extending away from an inner surface of the side wall; and (b) a device comprising a first element, the first element comprising: (i) a first surface; (ii) a second surface that is substantially opposed to the first surface; (iii) a channel extending between the first surface and the second surface; and (iv) a third surface extending between the first surface and the second surface, the third surface comprising one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge.
At least in part, the present disclosure further provides a method of manufacturing a beverage cartridge, the method comprising the steps of: (a) inserting into a beverage cartridge a device adapted for inserting into a beverage cartridge, the device comprising a first element, the first element comprising: (i) a first surface; (ii) a second surface that is substantially opposed to the first surface; (iii) a channel extending between the first surface and the second surface; and (iv) a third surface extending between the first surface and the second surface, the third surface comprising one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge; and (b) engaging the one or more recesses of the device to one or more protrusions extending away from an inner surface of the beverage cartridge and towards the centre of the beverage cartridge.
At least in part, the present disclosure further provides use of a device adapted for inserting into a beverage cartridge, the device comprising a first element, the first element comprising: (i) a first surface; (ii) a second surface that is substantially opposed to the first surface; (iii) a channel extending between the first surface and the second surface; and (iv) a third surface extending between the first surface and the second surface, the third surface comprising one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge, in the manufacture of a beverage cartridge.
This summary does not necessarily describe the entire scope of all aspects of the disclosure. Other aspects, features and advantages will be apparent to those of ordinary skill in the art upon review of the following description of specific embodiments.
In the accompanying drawings, which illustrate one or more exemplary embodiments:
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.
In this disclosure, the following terms have the following meanings.
“Biodegradable” means capable of degrading as a result of the action of naturally occurring microorganisms such as bacteria, fungi and algae.
“Compostable” means capable of undergoing degradation by biological processes during composting to yield at least CO2, water, and biomass and leaving no visible, distinguishable or toxic residue.
“Container” refers to an object adapted for holding a sleeve as understood according to the disclosure below.
Support DeviceReferring to
The third surface 118 comprises one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge. As shown in
The first element may be made of any suitable manufacturing material. As contemplated in the embodiment depicted in
Referring to
The third surface 218 comprises one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge. As shown in
Device 200 further comprises a second element 220 coupled to the first element 210, wherein the second element 220 is adapted for supporting a filter element (not shown). According to the embodiment depicted in
In another embodiment, extensions 222, 224, and 226 terminate at an apex. In other embodiments, the second element has two extensions terminating at a platform, two extensions terminating at an apex, four or more extensions terminating at a platform, or four or more extensions terminating at an apex.
According to the embodiment depicted in
The first element and second element may be made of any suitable manufacturing material. As contemplated in the embodiment depicted in
Referring to
Referring to
The container may be made of any suitable manufacturing material. As contemplated in the embodiment depicted in
Referring to
The sleeve 320 comprises an outer surface 320a and an inner surface 320b. In addition, sleeve 320 comprises a top perimetral ledge 321 adapted for engaging top perimetral ledge 312 of outer container 310. The sleeve 320 further comprises an opening 322 that is surrounded by top perimetral ledge 321, a base 323, and a continuous side wall 324 that extends between the base 323 and the top perimetral ledge 321. The shape of the sleeve 320 is complementary to the shape of the outer container 310. According to the embodiment depicted in
The sleeve 320 may be made of any suitable material. As contemplated in the embodiment depicted in
Referring to
According to the embodiment depicted in
Beverage cartridge 300 further comprises a filter element. The filter element may be made of any suitable material that is known in the art (such as paper), and is adapted for coupling to the support device (e.g. device 100, 200, or 330). According to an embodiment of the filter element, the filter element comprises: (i) a perimetral ledge adapted for engaging the first surface 333 of support device 330; and (ii) a body adapted for inserting through the channel 335. The body is further adapted for being supported by extensions 337, 338, and 339 on the side of the body and platform 341 at the base of the body. The body of the filter element defines a cavity (not shown) that is adapted for receiving thy beverage ingredients such as, but not limited to, tea leaves or coffee powder. According to an embodiment of the filter element, body of the filter element is frusto-conical in shape. However, in other embodiments of the filter element, the body of the filter element may be of any suitable shape including, but not limited to, conical, pyramidal, or frusto-pyramidal.
Referring to
In other embodiments, the beverage cartridge does not comprise an outer container, and the lid is adapted for coupling to the perimetral ledge of the sleeve.
Manufacture of Beverage Cartridge 300Using the beverage cartridge 300 depicted in
As previously described and according to the embodiment depicted in
The filter element (not shown) is coupled to the support device 330. The first surface 333, the surfaces of extensions 337, 338, 339 and platform 341 are slightly melted. The body of the filter element is inserted through the channel 335 until the side of the body of the filter element is in contact with the melted surfaces of extensions 337, 338, 339 and the bottom of the body of the filter element is in contact with the platform 341. The perimetral ledge of the filter element is placed in contact with the melted first surface 333. The filter element is pressed against the melted surfaces of extensions 337, 338, 339 and platform 341, and the support device 350 is then rapidly cooled, thereby securely engaging the filter element to the support device 330. The hot melt temperature is kept below a temperature that would damage, burn or otherwise affect the structural integrity of the filter element. In another embodiment, the filter element is securely engaged to support device 330 by heating one or more heat activated adhesives at least disposed between the perimetral ledge of the filter element and first surface 333. In other embodiments, the filter element is coupled to the support device 330 according to ways known to a person skilled in the art.
Referring to
Dry beverage ingredients (not shown) are then inserted into first chamber 370 and are prevented from entering the second chamber 380 by support device 330 and the filter element. Lid 360 is then coupled to the outer container 310. Specifically, heat-activated adhesive is disposed on top perimetral rim 311. The lid 360 is placed over the heat-activated adhesive, and heat is applied to securely engage the lid 360 to the outer container 310. In other embodiments, lid 360 is securely engaged to the beverage cartridge 300 by friction fit to the inner surface 320b of the beverage cartridge 300, or any other ways known to a person skilled in the art.
In other embodiments, the filter element is coupled to the support device after the support device is securely engaged to the inner surface of beverage cartridge.
Manufacture of Beverage CartridgeUsing an example where an outer container does not form a part of the beverage container, a sleeve is manufactured by vacuum forming. The formed sleeve comprises: (i) a top perimetral ledge adapted for engaging the lid; (ii) an opening that is surrounded by the top perimetral ledge; (iii) a base; and (iv) a side wall that extends between the base and the top perimetral ledge. In addition, the sleeve comprises one or more protrusions that extend toward the centre of the sleeve.
A support device is manufactured by injection molding. The formed support device comprises one or more recesses adapted for receiving the one or more protrusions of the sleeve. The formed support device may be device 100, device 200, or any embodiment thereof.
A filter element is coupled to the support device by melting the surfaces of the support device and adhering the filter element to the melted surfaces, heat-activated adhesives, or other ways known to a person skilled in the art.
The support device which is coupled with the filter element is inserted into the sleeve, and coupled to the inner surface of the sleeve. Specifically, the one or more recesses receives the one or more protrusions, thereby securely engaging the support device to the inner surface of the sleeve. The secured support device coupled with the filter element separates the sleeve into two chambers: a first chamber and a second chamber.
Dry beverage ingredients (not shown) are then inserted into the first chamber and are prevented from entering the second chamber by the support device and the filter element. A lid is then coupled to the outer container.
Use of the Beverage Cartridge 300Using beverage cartridge 300 as an example, beverage cartridge 300 is inserted into a compartment of a brewing machine. The brewing machine is activated. A fluid injector penetrates through the lid 360 and into first chamber 370, the first chamber 370 containing the dry beverage ingredients. The fluid injector does not touch the filter element. A fluid extractor penetrates through base 314 of the outer container 310 and base 323 of sleeve 320 and into the second chamber 380. The fluid extractor does not touch filter element 350. A brewing medium (e.g. hot water) is expelled from the fluid injector and into the first chamber 370. The brewing medium mixes with the beverage ingredients, and flavours from the beverage ingredients are extracted into the brewing medium. The brewing medium containing the extracted flavours percolates through the filter element and into second chamber 380. The fluid extractor extracts the brewing medium containing the extracted flavours from second chamber 380. The brewing medium containing the extracted flavours is then dispensed from the brewing machine as a drink beverage. The used beverage cartridge is expelled from the brewing machine and into a residential compost bin for residential composting.
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.
Claims
1. A device adapted for inserting into a beverage cartridge, the device comprising:
- (a) a first element, the first element comprising: (i) a first surface; (ii) a second surface that is substantially opposed to the first surface; (iii) a channel extending between the first surface and the second surface; and (iv) a third surface extending between the first surface and the second surface, the third surface comprising one or more recesses adapted for securely engaging to an inner surface of the beverage cartridge.
2. The device as claimed in claim 1, further comprising:
- (b) a second element coupled to the first element and adapted for supporting a filter element, the second element comprising: (i) a first extension extending away from the first element and along a first axis; and (ii) a second extension extending away from the first element and along a second axis; wherein the first axis and the second axis intersect.
3. The device as claimed in claim 2, wherein a platform extends between the first extension and the second extension, the platform adapted for supporting a part of the filter element.
4. The device as claimed in claim 2, wherein the first element and the second element are integrally formed.
5. The device as claimed in claim 2, wherein at least a part of the device is made of a compostable material.
6. The device as claimed in claim 5, wherein the compostable material is polylactic acid.
7. A beverage cartridge, the cartridge comprising:
- (a) a sleeve comprising: (i) a perimetral ledge; (ii) an opening surrounded by the perimetral ledge; (iii) a base; (iv) a side wall extending between the base and the perimetral ledge; and (v) one or more protrusions extending away from an inner surface of the side wall and towards the centre of the beverage cartridge; and
- (b) a device as claimed in claim 1.
8. The beverage cartridge as claimed in claim 7, wherein the one or more recesses receives the one or more protrusions, and wherein the device is securely engaged to the sleeve.
9. The beverage cartridge as claimed in claim 7 or 8, wherein the sleeve is made of a compostable material.
10. The beverage cartridge as claimed in claim 9, wherein the compostable material is polylactic acid.
11. The beverage cartridge as claimed in claim 7, further comprising an outer container into which the sleeve is inserted.
12. The beverage cartridge as claimed in claim 11, wherein the outer container comprises: (i) a perimetral ledge; (ii) an opening surrounded by the perimetral ledge; (iii) a base; and (iv) a sidewall extending between the base and the perimetral ledge.
13. The beverage cartridge as claimed in claim 12, wherein the sleeve perimetral ledge couples to the container perimetral ledge.
14. The beverage cartridge as claimed in claim 12, wherein the shape of the sleeve and the shape of the container are complementary.
15. The beverage cartridge as claimed in claim 13 or 14, wherein the sleeve is heat-melted to the container, and wherein the inner wall of the sleeve forms the inner wall of the beverage cartridge.
16. The beverage cartridge as claimed in claim 11, wherein the container is made of a compostable fibre material.
17. The beverage cartridge as claimed in claim 16, wherein the compostable fibre material is selected from the group consisting of: polylactic acid, bamboo, bagasse, and a combination thereof.
18. The beverage cartridge as claimed in claim 7, further comprising a filter element that is supported by and coupled to the device.
19. A method of manufacturing a beverage cartridge, the method comprising the steps of:
- (a) inserting the device as claimed in claim 1 into the beverage cartridge; and
- (b) engaging the one or more recesses of the device to one or more protrusions extending away from an inner surface of the beverage cartridge.
20. Use of the device as claimed in claim 1 in the manufacture of a beverage cartridge.
Type: Application
Filed: Apr 22, 2016
Publication Date: Nov 10, 2016
Inventor: Darren Joseph Footz (Vancouver)
Application Number: 15/135,808