Cartridges, systems and methods for preparation of beverages

A cartridge for preparation of a beverage comprising: a closed container defining a container volume; a filter to divide the container volume into an ingredient chamber volume and a filtrate volume; a beverage medium located in the ingredient chamber volume; and a guard element located in the filtrate volume; wherein the guard element is separately-formed from the closed container and located within the filtrate volume to define an outlet zone, the guard element being interposed between the filter and the outlet zone; wherein the guard element is configured to prevent encroachment of the filter into the outlet zone such that on piercing of a piercing surface of the cartridge by a piercing element of a beverage preparation apparatus the piercing element is enabled to be placed in fluid communication with the outlet zone without the piercing element contacting the guard element or filter. Associated methods and systems are also disclosed.

FIELD

The present application relates to cartridges, systems and methods for preparation of beverages.

BACKGROUND

Cartridges for use in the preparation of beverages are well known. For example, it is known to provide a cartridge for use in a beverage preparation machine which, in use, is pierced by a piercing element of the beverage preparation machine to allow hot water to flow through the cartridge to brew a beverage medium such as roasted ground coffee.

US2010/0303964 describes one such cartridge including a container, a beverage medium, a filter and a filter guard. The filter guard is arranged to be contacted by a piercing member and thereby be displaced upwardly during use. Displacement of the filter guard during use causes distortion of the filter and the beverage medium that may lead to inconsistent brewing of the beverage medium. Disruption to the beverage medium can lead to the formation of crevices in the beverage medium during brewing which allows the hot water to preferentially flow through the crevices rather than a uniform bed of the beverage medium. In addition, the need for the piercing element of the beverage preparation machine to displace the filter guard increases the force required to close a brew chamber of the beverage preparation machine and may also lead over time to blunting of the piercing element.

SUMMARY

The present disclosure provides a cartridge for preparation of a beverage comprising:

a closed container defining a container volume;

a filter located in the closed container to divide the container volume into an ingredient chamber volume and a filtrate volume;

a beverage medium located in the ingredient chamber volume; and

a guard element located in the filtrate volume;

wherein the guard element is separately-formed from the closed container and located within the filtrate volume to define an outlet zone, the guard element being interposed between the filter and the outlet zone;

wherein the guard element is configured to prevent encroachment of the filter into the outlet zone such that in use on full extension of a piercing element of a beverage preparation apparatus the piercing element is enabled to be placed in fluid communication with the outlet zone without the piercing element contacting the guard element or filter.

In one embodiment the guard element may be configured to provide physical support to at least a portion of the filter in use.

In one embodiment, the guard element acts as a filter guard to help prevent the filter being damaged during the piercing of the cartridge. In addition, the physical support of the filter coupled with the non-contact of the piercing element with the guard element or filter helps to prevent disturbance of the beverage medium during brewing or blunting of the piercer element.

The guard element may be configured to provide a clearance distance between the piercing surface and the filter, which is greater than a penetration distance of said piercing element into the closed container.

The guard element may comprise a filter support surface and at least one strut portion for spacing the filter support surface from the piercing surface of the cartridge.

In one aspect the strut portion may comprise a circumferential side wall. The circumferential side wall may comprise a plurality of elongate support ribs interposed by elongate filtrate apertures. In one aspect the circumferential side wall may be inwardly-tapered such that a diameter of the filter support surface is less than a diameter of a distal end of the circumferential side wall. In this aspect the guard element and/or outlet zone may be frustoconical in shape.

The filter support surface may comprise a plurality of elongate support ribs interposed by elongate filtrate apertures.

In one aspect the closed container may comprise a cup-shaped body and a lid, the cup-shaped body comprising a base defining the piercing surface and a side wall extending from the base to the lid, wherein the guard element comprises a filter support surface and at least one strut portion for spacing the filter support surface from the piercing surface of the cartridge, wherein a distal end of said strut portion is abutted into an angle formed between the side wall and the base. In this manner the guard element may be reliably located relative to the rest of the closed container. The guard element may also assist in increasing the structural strength of the cartridge as the guard element may form a load-bearing member, in particular for radial loads.

The side wall in the region of the base may be inwardly-tapered so as to retain the distal end of the strut portion. Use of an inward-taper is efficient in that no separate fixture is required to locate the guard element and the guard element may be easily assembled with the cup-shaped body in an automated process.

In another aspect the guard element may be configured to define an annular outlet zone. The guard element may comprise inner and outer circumferential side walls depending from a filter support surface of the guard element. The inner and/or outer circumferential side wall may comprise a plurality of wall sections interposed by filtrate apertures. The guard element may comprise a lower flange element defining a lower rim of the guard element. As in the above aspects the guard element may be insertable into a capsule having a cup-shaped body and a lid, wherein a the lower rim of the lower flange element is abutted into an angle formed between the side wall and the base. In this manner the guard element may be reliably located relative to the rest of the closed container. The guard element may also assist in increasing the structural strength of the cartridge as the guard element may form a load-bearing member, in particular for radial loads.

The side wall in the region of the base may be inwardly-tapered so as to retain the lower flange element. Use of an inward-taper is efficient in that no separate fixture is required to locate the guard element and the guard element may be easily assembled with the cup-shaped body in an automated process.

The side wall of the cartridge may be provided with a plurality of flutes defining a plurality of channels for directing filtrate downwardly towards the base of the cartridge.

The guard element may be rigid.

The guard element may be a one-piece moulding.

The cup-shaped body and/or guard element may be formed from polypropylene, polyester, polystyrene, nylon, polyurethane, acetal, acetal grade polyoxylene methylene copolymer (e.g. Centrodal C), other engineering plastics, composites, ceramics, 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), or poly lactic acids (PLA) (supplied by Cargill, Minn., USA). The cup-shaped body and/or guard element may comprise a laminate of materials. The laminate may comprise a layer providing a barrier to moisture and or gas transmission. An example is EVOH. The laminate may comprise one or more adhesive layers.

The guard element may be a stackable component. It may be provided with a feature to enable easy separation of individual guard elements from a stack of guard elements. In one aspect the feature comprises a spacing projection that defines a minimum clearance between stacked guard elements. The spacing projection may be located on or near a central axis of the guard element.

The filter may comprise a side wall and a base. The filter may be cup-shaped. The filter may be formed from one piece or one moulding. Suitable materials for the filter include woven and non-woven materials, paper, and cellulose as well as plastics such as polypropylene and polyethylene. The paper or cellulose material may contain fibres of another material, for example, polypropylene or polyethylene.

The lid may be formed from polyethylene, polypropylene, polyesters including polyethylene terephthalate, polyvinyl chloride, polyvinylidene chloride, polyamides including nylon, polyurethane, paper, viscose and/or a metal foil. The lid may comprise a laminate, be metallised or formed of copolymers. In one example, the lid comprises a polypropylene-aluminium laminate.

The disclosure finds particular application where the beverage medium is an extractable/infusible product such as roasted ground coffee or leaf tea. However, the beverage medium may alternatively be a water-soluble ingredient such as instant spray-dried or freeze-dried coffee, a chocolate powder, a milk powder or a creamer powder. Milk powders may include dried skimmed milk, part-skimmed milk, and whole milk, dried milk protein concentrates, isolates, and fractions, or any combination thereof. Creamer powders may 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. The powdered product may be agglomerated. As a further alternative the beverage medium may be a mixture of extractable/infusible ingredients and water-soluble ingredients, for example a mixture of roasted ground coffee and instant freeze-dried coffee.

In one aspect the closed container may comprise a cup-shaped body and a lid, the cup-shaped body comprising a base defining the piercing surface and a container side wall extending from the base to the lid, wherein the filter comprises an upper rim that is connected at or near a lid-end of the container side wall and/or between the container side wall and the lid and further comprises a filter side wall that is unconnected to the container side wall. The filter may comprise a base portion and the guard element may provide physical support to substantially the whole base portion of the filter.

In a particular aspect there is provided a cartridge for preparation of a beverage comprising:

a closed container comprising a cup-shaped body and a lid, the cup-shaped body comprising a base defining a piercing surface and a container side wall extending from the base to the lid, the closed container defining a container volume;

a filter located in the closed container to divide the container volume into an ingredient chamber volume and a filtrate volume;

a beverage medium located in the ingredient chamber volume; and

a guard element located in the filtrate volume comprising a filter support surface and a circumferential side wall for spacing the filter support surface from the piercing surface of the cartridge;

wherein a distal end of said circumferential side wall is abutted into an angle formed between the container side wall and the base;

wherein the guard element is separately-formed from the closed container and located within the filtrate volume to define an outlet zone, the guard element being interposed between the filter and the outlet zone;

wherein the guard element is configured to provide physical support to at least a portion of the filter in use and to prevent encroachment of the filter into the outlet zone such that on piercing of the piercing surface by a piercing element of a beverage preparation apparatus the piercing element is enabled to be placed in fluid communication with the outlet zone without the piercing element contacting the guard element or filter.

The present disclosure also provides a beverage preparation system comprising a beverage preparation apparatus and a cartridge as described in any of the aspects noted above, the beverage preparation apparatus comprising an outlet piercing element adapted to pierce a piercing surface of said cartridge to enable fluid communication between the outlet zone of said cartridge and an outlet of said beverage preparation apparatus without the piercing element contacting the guard element or filter of said cartridge.

The beverage preparation apparatus may be configured such that the outlet piercing element is off-set from a central axis of the piercing surface. This may be advantageous where the guard element comprises a centrally located spacing projection so as to avoid contact between the spacing projection and the outlet piercing element. Likewise, this may be advantageous where the outlet zone is annularly configured.

The present disclosure further provides a method for preparing a beverage comprising:

providing a closed container containing a beverage medium located in a ingredient chamber volume; said ingredient chamber volume being separated from a filtrate volume by a filter; said filtrate volume containing a separately-formed guard element;

piercing an inlet in an inlet piercing surface of the container using an inlet piercing element;

piercing an outlet in an outlet piercing surface of the container using an outlet piercing element;

supplying fluid through the inlet into the ingredient chamber volume to form a beverage from the beverage medium;

passing the beverage through the filter into the filtrate volume;

supporting the filter using the guard element to prevent encroachment of the filter into an outlet zone located between the guard element and the outlet piercing surface; and

discharging the beverage from the filtrate volume via the outlet zone and outlet.

DETAILED DESCRIPTION

As shown inFIG. 1, in a first aspect the cartridge1comprises a cup-shaped body2, a lid3, a filter guard6and a filter8.

The cup-shaped body2ofFIG. 1comprises a circular base4and an upwardly extending sidewall5that terminates at an upper rim21which defines an open upper end20of the cup-shaped body2. As shown inFIG. 2, the side wall5is provided on its inner face with a plurality of flutes28that project radially inwards so as to define channels29interposed between the flutes28which run down a substantial length of the side wall5from the open upper end20towards the base4. The side wall5is generally frustoconical in shape with a diameter at the open upper end20being larger than a diameter at the side wall5adjacent to the base4. An upper region of the side wall5adjacent to the upper rim21has an inwardly tapering section22extending downwardly from the upper rim21. In addition, the side wall5in the region of the base4is provided with an outwardly tapering section23. An upper end of the outwardly tapering region23connects to the remainder of the side wall5at an out-turned shoulder24.

The base4, illustrated for example inFIG. 4, is generally flat and includes an annular recess26which is provided at its outer periphery at an angle27between the base4and the side wall5. A flat portion4aof the base4provides a lower piercing surface40of the cartridge1.

A plurality of cup-shaped bodies2may be stacked together prior to assembly of the cartridges1.

The lid3comprises a disc that is bonded or otherwise sealed to the upper rim21of the cup-shaped body2to close the open upper end20of the cartridge1. The lid3defines an upper piercing surface43of the cartridge1.

In one embodiment, the filter8has a generally cup-shaped form having an upper filter rim50which is bonded or otherwise sealed to the cup-shaped body2either at or near the upper rim21. In a non-illustrated example the filter rim50is bonded between the upper rim21of the cup-shaped body2and the lid3. A filter side wall51may extend downwardly from the filter rim50and may be closed off at a lower end by a filter base52as illustrated. The filter8may be formed from a single piece or moulding of filter material.

The filter guard6may be formed as a separate component from the cup-shaped body2and filter8and may be located at a lower end of the cup-shaped body2as shown inFIGS. 1 and 2. As most clearly shown in the embodiment ofFIG. 3, the filter guard6comprises an upper portion9defining an upper surface10and a circumferential wall11which, in the illustrated embodiment, extends downwardly and outwardly from the upper portion9to terminate at a lower rim31. The upper portion9comprises an outer circumferential rim14and an inner circumferential rim15which are joined together by a plurality of radial bars12which define interposed upper apertures13. The inner rim15defines a central aperture16which extends downwardly through a downwardly extending tube17. The circumferential wall11may include a plurality of axially-orientated (or substantially axially-orientated) bars18which extend from the lower rim31to the outer rim14and which define interposed side apertures19. The filter guard6, illustrated inFIG. 3, is generally frustoconical in shape with a diameter of the lower rim31being greater than the diameter of the outer rim14.

The filter guard6may be rigid; meaning that it has sufficient structural strength so as not to undergo any substantial deformation during the use described below.

Advantageously, the filter guard6is shaped so as to be a stackable component prior to assembly of the cartridge1. The downwardly extending tube17serves to ensure that adjacent filter guards6are spaced slightly from one another when stacked to ensure ease of separation of each filter guard6from the stack.

As most clearly shown inFIG. 2, the lower rim31of the filter guard6may be located in the annular recess26of the cup-shaped body2with the lower rim31held in contact with the angle27between the side wall5and the base4.

In an exemplary assembly technique for the cartridge1as shown inFIG. 1, the filter guard6is first inserted into the open topped cup-shaped body2and pushed downwardly so as to engage the lower rim31as a push fit into contact with the angle27and recess26. Insertion of the filter guard6in one embodiment, is accommodated by flexure of the side wall5to allow the relatively rigid lower rim31to pass the smaller diameter of the cup-shaped body2at the level of the out-turned shoulder24. The side wall5is resilient in nature such that once inserted past the out-turned shoulder24the filter guard6is gripped and retained by the side wall5in contact with the angle27between the base4and the side wall5without the requirement for any additional bonding or connection means.

Next, the filter8is inserted into the cup-shaped body2through the open upper end20and bonded or otherwise connected to or near the upper rim21, for example by heat sealing.

As shown inFIG. 1, with the filter8in place a container volume of the cartridge1is divided into a beverage ingredient volume B to one side of the filter8and a filtrate volume C to the other side of the filter8. The filter guard6is located in the filtrate volume C beneath the filter8. The channels29formed between the flutes28form part of the filtrate volume C as they are ‘downstream’ of the filter8.

A portion of beverage ingredients7, such as roasted ground coffee, is filled through the open upper end20into the beverage ingredient volume B. The cartridge1is then closed by sealing the lid3to the upper rim21with or without sandwiching of the filter rim50therebetween. Two or more of the assembly steps described above may be combined into a single assembly process step.

InFIG. 1, when assembled the filter base52is physically supported by the upper surface10of the filter guard6. In one embodiment, the upper surface10of the filter guard6is configured to ensure that the material of the filter8does not extend into a portion of the filtrate volume C which can be considered an outlet zone D of the cartridge1. The outlet zone D is defined as the volume between the filter guard6and the base4of the cup-shaped body2. In one embodiment, filter guard6is configured to receive the piercing element such that, when the piercing element is fully extended in use, the piercing element does not move filter guard6. In one embodiment, filter guard6is configured to receive the piercing element such that, when the piercing element is fully extended in use, the piercing element does not contact filter guard6. In one embodiment, filter guard6defines an aperture56athat may be configured to receive a piercing element of a beverage preparation apparatus, such that, when the piercing element is fully extended into outlet zone D in use the piercing element is placed in fluid communication with the outlet zone D.

In use, as shown inFIG. 4, the cartridge1is inserted into a beverage preparation apparatus of known type in which an inlet piercing element55and outlet piercing element56are engaged with the cartridge1to permit brewing and dispensation. As shown, the inlet piercing element55pierces the upper piercing surface43of the cartridge1to form an inlet so as to provide fluid communication to the beverage ingredient volume B. The outlet piercing element56pierces the lower piercing surface40of the base4to form an outlet to provide an exit flow path for beverage formed from the beverage ingredient7to leave the cartridge1and thereafter the beverage preparation apparatus can be dispensed to a receptacle such as a cup. The outlet piercing element56may be offset from the centre of the cartridge1so as not to be impeded by the downwardly-extending tube17.

Aqueous medium, such as hot water, is injected into the cartridge1through the inlet piercing element55to contact the beverage medium7. A beverage extract is thus formed which passes through the filter8into the filtrate volume C. The beverage extract passes through the filter side wall51into the channels29where it is able to run downwardly and into the outlet zone D via the side apertures13in the filter guard6. Extract also passes through the filter8through the filter base52and into the outlet zone D through the upper apertures13and central aperture16of the filter guard6.

Advantageously, as shown inFIG. 4, a distance d between the base4of the cup-shaped body2and the lower face of the radial bars12of the filter guard6is greater than a penetration distance p of the outlet piercing element56into the cartridge1. This ensures that during use the outlet piercing element56does not contact either the filter guard6or the filter8. In one embodiment, aperture56aof filter guard6extends from base4toward upper surface10a distance that is greater than penetration distance p. As shown inFIGS. 1 and 4, the upper surface10of the filter guard6contacts the filter base52and provides a uniform clearance distance between the filter base52and the piercing surface40of the base4.

FIG. 5shows another aspect of filter guard6′ that may be incorporated into the capsule1in place of the filter guard6ofFIG. 3. In describing this aspect, features common to the previous aspect, in particular the configuration of the cup-shaped body2, lid3and filter8will not be described further and reference should be made to the passages above.

As before, the filter guard6′ may be formed as a separate component from cup-shaped body2and is located at a lower end of the cup-shaped body2as shown inFIG. 6. The filter guard6′ comprises an annular portion defining an upper surface10′, an outer circumferential wall11′ and an inner circumferential wall, both walls extending downwardly from the upper portion to adjoin a lower flange element. The lower flange element defines a lower rim31′. A central aperture16′ is provided within the upper surface10′. The inner circumferential wall comprises a plurality of wall sections18′ which define interposed side apertures19′.

The filter guard6′ may be rigid meaning that it has sufficient structural strength so as not to undergo any substantial deformation during the use described below.

Assembly of the cartridge1is as described previously except that the filter guard6′ is inserted such that the lower rim31′ is engaged in or close to the angle27of the cup-shaped body2. As above, the inwardly-tapered section23serves to maintain the filter guard6′ in the correct position.

As can be seen fromFIG. 6, when assembled the filter base52is physically supported by the upper surface10′ of the filter guard6′ which ensures that the material of the filter8does not extend into a portion of the filtrate volume C which can be considered an outlet zone D of the cartridge1. The outlet zone D is defined as the enclosed volume between the filter guard6′ and the base4of the cup-shaped body2.

Use of the cartridge1is as described above except that beverage extract passing through the filter8is channelled to the outlet piercer56via the side apertures19′ and the annular outlet zone D.

In a modification of the above aspect, the outer circumferential wall11′ may also be provided with apertures19′ for passage of beverage flow into the outlet zone D.

From the foregoing it will be appreciated that cartridges for preparation of beverages and components for such cartridges are provided.