BEVERAGE FILTER CARTRIDGE

Abstract

A beverage filter cartridge for use in a single serve beverage brewing machine, the cartridge including a open ended cup with an open top and closed bottom with a cup-shaped filter pouch containing a beverage material sealed to the inside thereof proximate to a top end. The top end includes a flange to which a cover is sealed to prevent spoilage of the beverage material by atmospheric oxygen. The cartridge includes a filter bag with a dry beverage material. The inner surface of the cup has a series of vertically oriented channels which allow for the brewed beverage to flow out of the sides of the filter bag and down the channels before exiting the cartridge at the bottom. The brewed beverage can flow out of the bottom of the cartridge either via the side of the filter bag through the channels or through the bottom of the filter bag.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/522,051, filed Aug. 10, 2011 and the benefit of U.S. Utility patent application Ser. No. ______, filed ______, 2012.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a cartridge for coffee, tea, and other beverages in amounts suitable for preparing single servings thereof in beverage makers designed to accommodate them.

2. Background of the Invention

Beverage filter cartridges used in specialty designed beverage makers are well known in the art. Essentially, beverage filter cartridges of this type have included an impermeable, yieldably pierceable base shaped like a cup. A self-supporting wettable filter element is disposed in the cup and may be permanently sealed to an interior surface thereof. The filter element subdivides the space within the cup into first and second chambers. The first chamber, the space within the filter element, is for the material from which a beverage may be made, such as ground coffee. The second chamber is for collecting the beverage dripping from the filter element after a liquid, such as hot water, has been introduced into the first chamber. An impermeable, yieldably pierceable, imperforate cover is sealingly engaged with the top of the cup to form an impermeable cartridge.

In use in the machines designed to accommodate the beverage filter cartridges, both the cover and bottom of the beverage filter cartridge are pierced with sharp, needle-like tubes. The piercing of the top cover admits hot water to the beverage filter cartridge. The brewed beverage flows out of the hole formed in the bottom of the cartridge by the other sharp, needle-like tube into a cup or mug for consumption by the user.

Machines and beverage filter cartridges of this general type have proven to be immensely popular as they permit single servings of coffee, tea and other beverages to be prepared quickly and easily. However, as is well known to those who are in the business of producing and marketing coffee, the current single serving cartridges have insufficient volume of ground coffee to produce a hearty cup of brewed coffee with the current configuration. In addition to there being an inadequate quantity of ground coffee, the flow of hot water through the cartridge tends to back up as small particles clog the bottom of the filter during the brewing process. As the coffee brews there is a poor flow of the brewed liquid as the bottom of the filter, where the great bulk of the brewed liquid exits the first volume clogs. There is a need to provide an improved cartridge which allows for a greater volume of beverage forming material, like ground coffee, to be included within the cartridge and to provide alternate flow paths for the brewed beverage to exit the cartridge as the bottom of the filter becomes clogged. The present invention has been developed to enable the use of a greater volume of roasted coffee in a beverage filter cartridge with a modified shape and alternate channels for flow of brewed coffee in order to permit the users to brew an improved cup of coffee with a contemporary single-serving beverage brewing apparatus.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to permit an increased volume of roasted and ground coffee to be used in a single-serving beverage pod.

It is another object of the present invention to permit an increased flow of brewed coffee or other beverage through alternate channels in the single-serving beverage pod.

It is still another object of the present invention to provide a single-serving beverage pod with an extended tip region for the roasted and ground coffee, tea or other beverage forming materials which adjusts the brewing characteristics of the beverage pod.

Still a further object of the present invention is a beverage pod with a series of radially oriented channels running downwardly around the perimeter of the beverage pod which enhance flow of the brewed beverage through the sides of the filter and down through the channels.

Yet another object of the invention is to form the outer side walls of the single-serve beverage pod with an oxygen blocking and scavenging additive which seals the beverage pod from the intrusion of oxygen, which causes the rapid reduction in quality of the roasted and ground coffee or tea or other beverage forming material.

It is a further object of the invention to improve the quality of beverages, and in particular, coffee, prepared with the use of single-serving technology.

Yet still a further objection of the invention is to provide a single-serving beverage pod which sits flat on a surface prior to use, with out gassing of carbon dioxide from the roasted coffee causing the upper cover to bow outwardly while the bottom cover lays flat.

To these ends, a first embodiment of the present invention is a beverage pod comprising a frustoconical sleeve, open at top and bottom, and having a larger diameter at the top than at the bottom. The sleeve terminates at the top at a flange. The flange extends outwardly around the top of the sleeve. A filter pouch for a beverage material such as ground coffee or tea leaves, is disposed within the sleeve. The top portion of the filter pouch is sealed to the inside surface of the sleeve proximate to the top thereof. Once beverage material has been placed in the filter pouch, a cover is sealed to the flange extending about the top of the sleeve to provide an oxygen barrier at the top of the sleeve. A cover is also sealed to the bottom of sleeve to form a sealed beverage pod. The top and bottom covers are pierced by a tubular needle which is a part of a beverage brewing machine.

The beverage pod may also include a plug, or stopper, which is inserted into the bottom edge of the sleeve to seal the bottom of the sleeve. The plug may be held within the bottom of the sleeve by an interference or screw fit, or be a part of the bottom cover, providing an oxygen barrier at the bottom of the sleeve. The plug may incorporate a one-way degassing valve of the types long-used in packages of coffee products, in order to permit gases escaping from the contents of the filter pouch to vent from the sleeve, so that pressure will not build up and cause any seal to rupture, all without permitting any oxygen to enter the sleeve. The plug is intended to be removed from the bottom edge of the sleeve immediately prior to use in a beverage brewing machine.

In a variation of this first embodiment, the beverage pod does not include a plug or stopper. Instead, the bottom of the frustoconical sleeve is open, so that the beverage pod may be used without first removing a plug. In this variation, a plurality of beverage pods, for example six or twelve of them, are provided in a resealable package of an oxygen-barrier material. The resealable package preferably includes a one-way degassing valve.

A second embodiment of the present invention is a beverage filter cartridge comprising a beverage filter pod and a reusable sleeve.

The beverage filter pod comprises a cap and a filter element for holding materials from which a beverage may be brewed. The cap is generally circular in shape and is made of a biodegradable material. The top of the cap has a central recessed portion which is thinner than other portions of the cap and designed to be pierceable by a sharp, needle-like tube in a single serving, beverage-making machine.

On the underside of the cap is a surface oriented at an oblique angle relative to the top of the cap, and extending circumferentially around the underside. The filter element is sealed to this surface once it has been filled with a brewable ingredient. The cap finally also has a flange extending about the perimeter of the cap above the oblique surface. The flange is used to stabilize the beverage filter pod on the sleeve.

The sleeve, perhaps made of plastic or some other durable material, is designed to be reused many times. In this regard, the use of the present beverage filter system will contribute less non-biodegradable waste than conventional beverage filter cartridges.

The sleeve may be frustoconical in shape and have open ends. At the top end, a shoulder extends around the inside surface of the rim. The shoulder has a surface making an oblique angle relative to the plane formed by the rim. The surface of the shoulder cooperates with the oblique surface on the underside of the cap to stabilize the cap when the beverage filter pod is disposed on the sleeve. The flange extending around the cap enhances this stability.

At the lower end of the sleeve is a flange oriented obliquely inward toward the axis of the sleeve both for stability of the sleeve as a whole and to prevent liquid from getting trapped within the sleeve. Within the sleeve proximate to but recessed from the lower end are cross beams which are provided to prevent a saturated filter element from sagging low enough to be punctured or torn by any element of the coffee maker. The upper surfaces of the cross beams are crowned or peaked to ensure that liquid on them will roll off and downward out of the sleeve.

In a fifth embodiment of the beverage filter cartridge, the outer cup has a plurality of spaced vertical vents disposed circumferentially about the lower portion thereof. The inner surface of the outer cup has vertically oriented channels, each of which leads to one of an equal number of circumferentially disposed holes on the bottom. A central hole is also provided it the bottom. The holes and vents permit a brewed beverage to drain from inside the beverage filter cartridge.

Finally, in a sixth embodiment of the beverage filter cartridge, the outer cup has a recessed bottom with a plurality of circumferentially disposed holes. Within the outer cup is a plurality of vertically oriented channels, each leading to one of the holes in the bottom. The lower rim of the outer cup may be sealed with a bottom which is pierced by the bottom needle of the beverage making machine, or may have a plug, which may be removed prior to use on a coffee brewing machine. The plug may include a one-way degassing valve.

In another preferred embodiment of the beverage filter cartridge, the body of the cartridge is formed as a frustoconical shell which is of greater diameter at the top than at the bottom, with a series of vertically oriented channels on the inside of the shell arranged radially around the body, each of the channels extending below the bottom of the filter and the bottom of the filter extending vertically below the plane that the bottom needle reaches in a central portion, the central portion being positioned inside the radius from the center that the bottom needle is positioned, so that the needle will not pierce the filter in the central portion or elsewhere and the beverage material in the central portion enhance the fill capacity of the beverage cartridge, enhances the quality of the flow rate during the brew and creates a significant flow of brewed beverage out of the sides of the filter into the channels on the way out of the beverage cartridge.

In another embodiment of the invention, the beverage filter cartridge is formed with a modified bottom in which a dome is formed in the center of the bottom, projecting upwardly to support the filter in the center of its bottom so that when the lower needle of the single cup coffee machine pierces the bottom surface of the beverage cartridge it does not pierce the filter too. By forming the dome in the center of the bottom of the beverage cartridge the structure stiffens the base of the beverage cartridge to allow easier piercing of the bottom, while protecting the filter which allows larger amounts of coffee or other beverage material to be placed in the beverage cartridge, thereby producing stronger, bolder coffee without altering the size or shape of the outside of the beverage cartridge so that it still tits in the same single cup machines as traditional beverage cartridges.

The invention accordingly comprises the features of construction, combinations of elements and arrangements of part and processes which will be exemplified in the constructions and processes as hereinafter set forth, and the scope of the invention will be indicated in the

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described in more complete detail with frequent reference being made to the figures identified below.

FIG. 1 is a front elevational view of a beverage cartridge constructed in accordance with a preferred embodiment of the invention;

FIG. 2 is perspective view of a beverage cartridge constructed in accordance with the embodiment of FIG. 1;

FIG. 3 is a cross-sectional view of a beverage cartridge taken along line A-A of FIG. 2;

FIG. 4 is a perspective view of the beverage cartridge of the embodiment of FIG. 1;

FIG. 5 is another perspective view of the beverage cartridge of the embodiment of FIG. 1;

FIG. 6 is a top plan view the beverage cartridge of the embodiment of FIG. 1;

FIG. 7 is a front elevational view of a filter utilized in the beverage cartridge in the embodiment of FIG. 1;

FIG. 8 is a cross sectional view of a beverage cartridge with a filter and dry beverage making material shown in accordance with the embodiment of FIG. 1

FIG. 9 is a perspective view of a filter bag used in the cartridge in accordance with the invention;

FIG. 10 is a perspective view of a beverage cartridge in accordance with another embodiment of the invention;

FIG. 11 is a perspective view of a beverage cartridge in accordance with another embodiment of the invention;

FIG. 12 is a perspective view of a beverage cartridge in accordance with another embodiment of the invention;

FIG. 13 is a perspective view of a beverage cartridge in accordance with another embodiment of the invention;

FIG. 14 is a perspective view of a beverage cartridge in accordance with another embodiment of the invention;

FIG. 15 is a perspective view of a beverage cartridge in accordance with another embodiment of the invention;

FIG. 16 is a side elevational view of the beverage cartridge of FIG. 15;

FIG. 17 is a bottom plan view of the beverage cartridge of FIGS. 15 and 16;

FIG. 18 is a top elevational view of the beverage cartridge of FIGS. 15, 16 and 17; and

FIG. 19 is a cross sectional view of the beverage cartridge of FIGS. 15, 16, 17 and 18 taken along line 19-19 of FIG. 16.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference is made to FIGS. 1-7, wherein the single serving beverage container, generally indicated as 100, constructed in accordance with a preferred embodiment of the invention, is depicted. As seen in FIG. 1, beverage cartridge 100 includes central body 112, upper flange 114, top number 116 and bottom cover 118. In the current preferred embodiment the top cover 116 and the bottom cover 118 are oxygen impermeable layers which can be made either of foil or plastic layers which seal to the flange 114 at the top of body 112 and to the bottom of body 112 as shown more particularly in other views.

Reference is next made to FIG. 2, which is a perspective view of beverage cartridge 100 without top cover 116. As can be seen, body 112 has a series of channels 120 vertically oriented running from proximate the top surface of body 112 to proximate the bottom of body 112. The channels are made in the sides of beverage cartridge 100 in a fashion best seen in FIGS. 3, 4 and 5.

With reference to FIG. 4, the channels 120 are oriented radially around the circumference of body 112 extending from near the upper flange 114 to the bottom section of body 112. As is best seen in FIGS. 3, 4 and 5, the bottom surface of beverage cartridge body 112 includes a cage used to support the filter and beverage grinds placed therein. The cage is formed by ribs 132 extending to a central support platform 128 with an inner dropped cage volume 126 formed by vertical cage portions 122 and horizontal cage portions 124.

The beverage machines (not shown), in accordance with the prior art, have an upper needle used for injecting hot water into the beverage cartridge 100 by piercing upper cover 116 and a lower hollow needle (not shown), which is used to pierce a hole in the bottom cover 118 to allow the beverage to drain out of the cartridge 100. The lower needle is positioned off-center from the bottom center of the cartridge. Because the cartridges are not indexed into a particular orientation, the needle can, thus, pierce any portion of the bottom cover 118, which is the appropriate distance from the center where the needle is located. The traditional types of beverage cartridges, such as the Keurig brand K-Cup beverage cartridges, the filter with the ground coffee is maintained an adequate distance from the base of the cartridge so that when be bottom needle pierces the base of the Keurig brand K-Cup cartridge the needle does not also pierce the filter containing the coffee grinds. However, this approach limits the amount of coffee which can be utilized in the beverage cartridge because the overall volume of the beverage cartridge is limited to the size which fits within the beverage machine. However, by utilizing the central cage, which extends downwardly below the level at Which the lower needle pierces, but within the radius at which it resides, an additional volume is achieved for coffee or other dry material to brew a beverage. In addition to the benefit of additional volume of the dry particles, by adding a deeper central brewing area, the finer and/or slower dissolving particles within the filter begin to clog the bottom surfaces of the filter adding additional resistance. The increase in resistance to the flow of the brewed beverage redirects the water flow creating internal turbulence, which leads the liquid to be disbursed through the outer side vertical channels 120 of the cup. The vertical channels provide a path for the brewed beverage to flow through all of the filtered surfaces simultaneously.

The bottom basket in the design formed by vertical members 122 and horizontal members 124 produce several important benefits measured against designs that do not have this feature. This basket approach includes an increased internal fill volume while maintaining a needle barrier and support for the filter. It provides for an increased open area for brewed liquid to flow through with balanced resistance. The horizontal portion 124 of the basket provide a sealing area for the bottom, covered to maintain a flat bottom surface area so the cup sits level on a counter or other flat surface. The top cover 116 would flex upward from the internal degassing pressure and not the bottom surface, which is bound to the rigid horizontal member 124. The sealing area on the bottom surface of the cartridge 100 creates more precise tension.

With the cage system one can put in as much as 13.5 grams of coffee, 10 grams of tea or 20 grams of other soluble products for optimal flavor and intensity by maximizing the internal volume. This allows the brew time to stay within the optimal 45 to 90 second range. Testing the cage system in accordance with the invention has revealed high levels of total dissolved solids for all beverages.

Reference is next made to FIG. 8, wherein a cross-sectional view of the beverage cartridge 100 in accordance with the invention is depicted in the beverage making machine with hollow needle 50 shown piercing the bottom cover 118 of cartridge 100. The remainder of the beverage making machine, constructed in accordance with the prior art is not depicted. A variety of machines operate in a similar fashion, one of which is the Keurig brand K-cup system brewing machines. Needle 50 is located a distance from the center of the base of cartridge 100 and the basket horizontal supports 124 and bulge section 151 of filter 150 are not pierced by needle 50 in use. In this way, the additional volume created in the bulge region allows additional coffee grounds or other beverage making dry material to fit within the cartridge 100 without affecting the overall volume of the cartridge or creating a situation where the needle 50 might inadvertently pierce the filter 150, thereby allowing the grinds to enter the brewed beverage. The beverage making machine is a conventional machine such as that sold by Keurig under the brand K-Cup brewing system. The machines are designed to receive a standard size beverage cartridge. They have the needles at the top to inject hot water or other heated liquid into the top of the cartridge (not shown) and the bottom needle 50 shown herein, which pierces the bottom of cartridge 100 to allow the brewed beverage to exit from the cartridge.

In the current preferred embodiment, the cartridge 100, including the side wall 112, flange 114 and cage members 122 and 124, are all formed from high density polyethylene (HDPE), which can be recycled under the number sign 2 symbol. In a preferred embodiment, the cup will be injection molded with the ability to add oxygen scavenging additives to the mix. When added, these additives will scavenge residual oxygen in the cup and act as an additional barrier, preventing oxygen from entering the cup and extending its shelf life.

The comparisons that were made between the existing, current market products, such as the Keurig brand K-Cup cartridges and the beverage cartridge in accordance with the invention were made using existing brewers, such as the Keurig brand K-Cup machines. Testing of various designs, including ups with varying channels mentioned and hole configurations yielded substantially different and unsatisfactory results. Brew times exceeding 90 seconds are not conducive to the convenience nature of the single serving market segment. In addition, they tend to produce a bitter-tasting, overly extracted beverage. Also, the flow characteristics of the cup designed with the cage produce a good balance of total dissolved solids and flavor within the optimum brew time for products of this type. The beverage container is suitable for use with coffee, tea or other soluble products.

The additive which is utilized as the oxygen scavenging material has been used primarily in PET applications for the beverage industry. However, using it with the monolithic HDPE material designed for use with the beverage cartridge 100 is expected to be able to maintain peak freshness for a minimum of 9 to 12 months. The brew time was measured using a stopwatch to determine the effects of different configurations of the beverage cartridge on brew time. Total dissolved solids was measured using a total dissolve solids measuring tool utilized in the industry and flavor was measured using a specialty coffee association cupping criteria.

The use of the channels 120 and cage 140 together were derived to address the internal resistance during the brewing process of the traditional beverage cartridge and the desire to increase the volume of coffee and enhance the flavor of the brewed coffee beverage, without having the bottom needle puncture the filter. If the filter is punctured, then the grinds enter the brewed beverage, which is gritty and generally not acceptable. Because the beverage cartridge 100 constructed in accordance with the invention is an injection molded product with more wall stiffness than the conventional Keurig brand K-Cup design, the wall thickness can be made less creating an internal volume of the cup can be made slightly larger, with a slightly wider cup. Top and bottom dimensions of the beverage cartridge 100 have the same dimensions as the K-Cup so that it fits smoothly into the Keurig beverage machines, but has increased internal dimension in the middle section of the cup.

As seen in FIG. 4, the channels 120 are oriented radially about the circumference of the body 112 of cartridge 100. The channels run down to openings 130 proximate the support shelf 128 and horizontal ribs 132. In this way, with the filter in place inside the cartridge, the vertical side walls of the filter press up against the inside surface of body 112 with the channels 120 creating a volume to allow the brewed beverage to exit the filter and freely run down the inside of cartridge 100 and out the bottom of openings 130 to the bottom of the cartridge. The open channels running vertically along the inside of body 112 create a slight vacuum effect helping to draw the brewed beverage out of the sides of the filter 150 so that more of the heated water comes in contact with relatively fresh and dry beverage forming material while maintaining a good flow rate through the cartridge 100. As the bottom of the cartridge has been pierced in the beverage making process by the lower needle 50 of the beverage machine, the brewed beverage flows out of the bottom of the cartridge. The brewing process can be simplified to be the introduction of hot water into contact with the beverage forming material which causes the beverage to be brewed as the solids and oils in the beverage forming material join with the water and exit the beverage cartridge as the brewed beverage.

As seen in FIG. 5, the horizontal section 124 formed in a crossing pattern at the base of the basket or cage 140, is generally coplanar with the base of body 112 so that the bottom cover 118 can be secured both to the bottom perimeter of body 112 and the flat bottom surface of members 124. This assures that, as the roasted and ground coffee outgases, producing carbon dioxide, the expansion of volume within the cartridge results in a bowing outward of only the upper cover 116 rather than lower cover 118. By fixing lower cover 118 both in the center and around the perimeter, the bottom cover retains its generally flat orientation so that the cartridge 100 will sit securely on its base.

Reference is next made to FIG. 7, which shows the filter bag 150, which sits inside of cartridge 100 and is secured at its upper portion 153 to the inside of body 112, proximate flange 114. The filter 150 includes lower bulge portion 151, which fits within the basket region 140 formed by members 122 and 124. A ground coffee, tea or other dry product 152 is shown inside of filter 150. In practice, the cartridge 100 as shown in FIG. 1 would be sealed with filter 150 with coffee, tea or other dry material 152 inside in a Nitrogen environment so that oxygen is prevented from coming in contact with the ground coffee or tea. Oxygen tends to cause the coffee or tea to degrade quickly and become stale, losing much of the volatile oils which provide the distinctive aromas and flavors of coffee and tea.

The cartridge 100 is designed to have primary and secondary paths for the flow of liquid. Initial flow will be injected in the center of the cup (directly below the water inlet needle which while not shown is in the center of the top of the cartridge 100). This is where the deepest bed of dry particles is found, with the additional depth in the central bulge region 151. During the brew cycle, the finer and or slower dissolving particles begin to clog the bottom surfaces of the filter paper 150 adding intentional resistance. The increase in resistance re-directs the water flow creating internal turbulence which leads the liquid to be dispersed through the outer side vertical channels 120 of the cup 100. The vertical channels 120 provide a path for the brewed beverage to flow through all filtered surface areas simultaneously. The bottom basket design 140 produces a number of important benefits when measured against designs that do not have this feature or have a “flat or convex” patterned bottom.

(1) Increased internal fill volume while maintaining a needle barrier and support for filter.

(2) Increased “open” area for brewed liquid to flow through with balanced resistance.

(3) Sealing area for the bottom sealing material to maintain a “flat” bottom surface area so cup sits level on the counter. We want the top lid to flex upward from internal degassing pressure and not the bottom.

(4) Sealing area creates more precise tension to guarantee bottom needle cleanly punctures 100% of the time even with dull needles.

(5) Allows the use of either conventional or biodegradable filter material.

This system allows us to place as much as 13.5 grams of coffee, 10 grams of tea and or 20 grams of soluble product for optimal flavor and intensity by maximizing the internal volume. This allows the brew time to stay within the optimal 45-90 second range. Tests have revealed high levels of TDS (Total dissolved solids) for all beverages using the beverage cartridge 100 in accordance with the invention.

A preferred choice for cup materials is HDPE which will be recycled under the #2 symbol. This material is injection molded with the ability of adding oxygen scavenging additives to the mix. When added these additives will scavenge residual oxygen in the cup and act as an additional barrier, preventing oxygen from entering the cup and extending its shelf life. A current preferred additive, is ValOR® Active Bloc 100 barrier resin from Valspar Corporation of Pittsburgh, Pa., to give it improved oxygen barrier characteristics. PLA (poly-lactic-acid) Blend Resin from C-Stone LLC of San Diego, Calif., ABS (acrylonitrile butadiene styrene), PHA, or polystyrene may also be used as the plastic resin material, to which the oxygen barrier material may be added.

Comparisons have been made versus the current market products using existing brewers. Testing of various designs including cups with varying channel dimensions and hole configurations yielded substantially different and unsatisfactory results. Brew times exceeding 90 seconds are not conducive to the “convenience” nature of this product and market segment. In addition they produce a bitter tasting overly extracted beverage. The flow characteristics of the disclosed cup design allow one to produce the best balance of TDS (Total Dissolved Solids) and flavor within optimal brew time for products of this type.

Turning now to these figures, FIG. 1 is a side view of the beverage filter cartridge 10 of the first embodiment of the present invention. The beverage filter cartridge 10 includes a frustoconical sleeve 12, which, as will be shown below, is open at its top and bottom and has a larger diameter at the top than at the bottom. At the top of the frustoconical sleeve 12 is a flange 14, which extends outwardly around the top. A cover 16 is sealed to the flange 14 to provide an oxygen barrier at the top of the frustoconical sleeve 12. The cover 16 may be of a laminated foil material and is pierceable by an inlet needle on a beverage brewing apparatus. The cover 16 may be removable for recycling.

The frustoconical sleeve 12 also includes a shelf 24 having openings to enable a brewed beverage to drain therethrough. Among these openings are openings 26, one for each channel 22, which allow brewed beverage flowing along the channels 22 to drain quickly through the shelf 24. Other openings 28 allow brewed beverage seeping from the bottom of a filter pouch to drain through the shelf 24.

FIG. 5 is an exploded cross-sectional view of the frustoconical sleeve 12 and plug 18 shown in FIG. 4, it will be noted that proximate to the flange 14 at the top of the frustoconical sleeve 12 and above the channels 22 is a smooth area 30 to which the top of a filter pouch is sealed. At the bottom of the frustoconical sleeve 12 is a bead 32 which is provided to hold the plug 18 in place in a manner to be described below. Bead 32 extends circumferentially around the inside of the bottom of the frustoconical sleeve 12, except where interrupted by notches 20.

FIG. 9 is a perspective view of a filter pouch 150. As shown, the filter pouch 150 is generally cup-shaped, and does not have corrugations. Filter pouch 150 may incorporate a heat sealable adhesive, so that the top portion 152 may be heat sealed to the smooth area 113 on the inside of the frustoconical sleeve 112 proximate to the flange 114. Filter pouch 150 preferably does not extend from smooth area 113 as far as the top surface of the shelf 128 in FIGS. 3 and 4. Filter 150 is drawn without bulge section 151 as seen in FIG. 8 for ease or representation and as an alternate approach. The filter 150 can be without the bulge section 150 which reduces the flow but still allows the use of the channels 120 to increase the alternate flow paths.

Rather than having the vertically oriented channels 120, the inside of the sleeve 112 may be provided with spiraling channels 153, as shown in FIG. 10, or with vertically oriented channels 154, as shown in FIG. 11. Alternatively, spiraling ridges 156 may be provided on the inside surface of sleeve 112, as shown in FIG. 12, or vertically oriented ridges 158, 160, as shown in FIGS. 13 and 14, with desired amounts of spacing separating them from one another. Instead of ridges 156, 158, 160, the inside surface of sleeve 112 may be provided with bumps or moguls for the same purpose, namely, to ensure that some space will be available between the inside of the sleeve 112 and the filter 150 for the drainage of a brewed beverage downward out of the sleeve 130.

Reference is next made to FIGS. 15-19 which show another embodiment of the invention in which the cup is formed with a closed bottom 218 which includes a dome 230 which is formed as a hollow member with the central portion projecting upwardly from the bottom with a rounded upper surface against which the lower central portion of the filter(not shown) will drape and rest when water is introduced into the top of the beverage container 200. The dome 230 projects up high enough so that even when the filter and beverage material in it are filled with water the filter will still stay supported high enough over the portions of the base 218 which are pierced by the bottom needle in use. This allows for significant additional amounts of beverage material to be placed in the beverage container 200 which will allow the strength of the brew made to be significantly enhanced. One of the major complaints about the original Keurig K-cup beverage containers was the weakness of the coffee they made due to the limitations of the volume of coffee that could be used in their beverage containers With the beverage container of the embodiment of FIGS. 15-19 one is able to put as much as 15 or 16 grams of beverage material into the cup as compared to the 11-12 grams of beverage material available in the original Keurig K-cup beverage containers. This significant difference enabled by the organization of the new beverage container 200 produces a far more robust beverage than was possible with the earlier beverage containers.

As seen in FIG. 15 the beverage container 200 includes a central section 212 and top flange 214 which is configured to receive a top cover(not shown) like in the other embodiments. The top cover is generally a foil piece which provides an oxygen resistant seal to maintain the very low oxygen content within the beverage container 200. As a practical matter, the industry standard is that there be less than 3% of residual oxygen content in the sealed beverage container when it is filled with the filter and beverage material because any greater amount of residual oxygen will cause the beverage material to become stale quickly. This would negatively affect the quality of the beverage made form the beverage material. In production, once the filter and beverage material are inserted in the beverage container, and before the top lid is sealed to the top flange 214, the container is given a nitrogen flush which replaces the air, which includes about 20% by volume oxygen with nitrogen to force out the oxygen found in the air. If done properly the residual oxygen remaining in the sealed beverage container is no more than 3% by volume.

As seen in FIG. 16, there is a top rim 215 under the flange 214 which stiffens the top of the beverage container 200. A series of channels 220 go generally vertically from the bottom of the top rim 215 to the bottom 218 of the beverage container 200. FIGS. 17 and 18 show views of the beverage container 200 from the top and bottom. FIG. 19, which is a cross sectional view taken along lines 19-19 in FIG. 16 shows how the dome 230 is situated at the bottom 218 of beverage container 200. Dome 230 as can be seen is hollow, with the bottom surface of the cup formed so that it rises up in its center to form the dome 230. The radius of the dome is designed to such that the bottom needle of the machine used to make the beverage(not shown) will pierce in the bottom surface 218 outside of the radius of the dome. Thus it will pierce the flat bottom surface and not in the region of the dome 230. And, when the needle pierces bottom surface 218 it will not pierce the filter (shown in other Figures), which will be supported on the top of the dome 230 and even if filled with water will not droop down into the needle.

The embodiment of FIGS. 15-19 only requires a filter and the beverage material to be placed in it before the oxygen is removed by nitrogen flushing and then sealed with a lid on the top attached to the flange 214. There may also be nitrogen flushing after the filter is put in and before the beverage material is inserted. The side walls 212 and top rim 215 are gently angled so that the beverage container 200 can be stacked with a very small overlap, with adjacent beverage containers 200 riding up so that the flange 214 from one beverage container rests up against the bottom of the adjacent beverage container's top rim 215. This allows for high concentration stacking of the beverage containers which can decrease shipping and packaging costs associated with the beverage containers. The channels 220, as in some of the other embodiments provide a pathway for the brewed beverage to exit the filter higher in the cup and then flow down through the channels to the base of the cup and out the lower needle hole pierced by the lower needle.

The cup 200 described above is made using a thermoforming technique with a layer of EVOH barrier material sandwiched between two layers of polypropylene. This is preferable to the use of polysterene which is not recyclable.

It will thus be seen that the objects set forth above, among those made apparent in the preceding description, are efficiently obtained, and, since certain changes may be made in the above construction without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative, and not in a limiting sense.

It is also understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween.

Claims

1. A single-serving beverage pod for use in a beverage making machine having an upper needle for injecting hot water into the beverage pod and a lower needle for allowing a brewed beverage to exit the beverage pod, comprising:

an open ended cup having an open top and a closed bottom, with the cup having a flange extending around said top;

a filter, said filter being generally cup-shaped and having an upper portion, said upper portion being sealed within said cup proximate to said top;

a dome, upwardly facing, extending within the cup from the bottom thereof for supporting the filter a distance above the bottom of the cup sufficient to prevent the lower needle from piercing the filter;

a beverage material within said filter; and

a top cover attached to said flange.

2. The single-serving beverage pod of claim 1 wherein the top cover comprises an oxygen barrier material.

3. The single-serving beverage pod of claim 1 wherein the cup comprises a high density polyethylene with an oxygen scavenging additive.

4. The single-serving beverage pod of claim 1 wherein inward of a sidewall of the cup, the bottom of the cup rises substantially vertically, terminating in a rounded, curved surface, defining the dome.

5. The single-serving beverage pod of claim 1 wherein the filter fills the space within the cup above the dome.

6. The single-serving beverage pod of claim 1 further having a side wall including a series of vertically oriented channels.

7. The single-serving beverage pod of claim 6 wherein the vertically oriented channels extend from proximate the top of the cup to a point proximate the bottom of the cup.

8. The single-serving beverage pod of claim 1 wherein a portion of the bottom of the cup defines a flat surface that is substantially parallel to the flange, wherein the portion extends radially inward of a sidewall of the cup, the dome rising from a radially inward-most edge of the first portion and wherein, as between all diametrically opposed points on a surface of the dome, a curve defined by the surface is characterized by a first derivative having only one change in sign.

9. The single-serving beverage pod of claim 1 wherein the beverage pod comprises a layer of EVOH barrier material sandwiched between two layers of polypropylene.

10. The single-serving beverage pod of claim 1 wherein the dome does not collapse when the hot water is injected.

11. The single-serving beverage pod of claim 1 wherein a hole in the bottom of the cup resulting from the lower needle of the beverage making machine is formed outside of a perimeter of the dome.

12. A single-serving beverage pod for use in a beverage making machine having an upper needle for injecting hot water into the beverage pod and a lower needle for allowing a brewed beverage to exit the beverage pod, comprising:

an open ended cup having an open top, a sidewall, and a closed bottom;

a filter, the filter having a cup shape and wherein an upper portion of the filter is attached to the cup proximate to the top thereof;

a dome, upwardly facing, extending within the cup from the bottom thereof, wherein the dome is non-collapsible to support the filter a distance above the bottom of the cup sufficient to prevent the lower needle from piercing the filter;

a beverage material within the filter; and

a top cover attached to the top of the cup.

13. The single-serving beverage pod of claim 12 wherein there are no openings in a surface of the dome.

14. The single-serving beverage pod of claim 12 wherein the sidewall comprises a plurality of vertically oriented channels.

15. The single-serving beverage pod of claim 12 wherein a slope of a curve defined by a surface of the dome within a region between a base and apex thereof changes monotonically.

16. A single-serving beverage pod for use in a beverage making machine having an upper needle for injecting hot water into the beverage pod and a lower needle for allowing a brewed beverage to exit the beverage pod, comprising:

an open ended cup having an open top, a sidewall, and a closed bottom;

a filter, the filter having a cup shape and wherein an upper portion of the filter is attached to the cup proximate to the top thereof;

a dome, upwardly facing, extending within the cup from the bottom thereof, wherein there are no openings through a surface of the dome;

a beverage material within the filter; and

a top cover attached to the top of the cup.

17. The single-serving beverage pod of claim 16 wherein the dome is not collapsible.

18. The single-serving beverage pod of claim 16 wherein a slope of a curve defined by a surface of the dome within a region between a base and an apex thereof changes monotonically.

19. The single-serving beverage pod of claim 18 wherein the dome supports a bottom of the filter, and further wherein a height of the dome is sufficient to prevent the lower needle of the beverage making machine from piercing the filter.

20. The single-serving beverage pod of claim 16 wherein the sidewall comprises a plurality of vertically oriented channels.