Loose coffee apparatus, system and method

An infusion container (30) for use with a brewer (20). The infusion container (30) includes a body portion defining at least a portion of a cavity therein. At least a portion of the body being liquid permeable. The infusion container liquid permeable portion facilitates brewing a beverage by allowing water to pass through the infusion container. The infusion container may be an individual structure which can be placed in and removed from the holder (30). Additional components or group of components for use with the beverage holder (30). The infusion container provides structures and methods facilitating convenient use of a brewer which allows the user to use the type of substance and quantity of substance of their choice and efficiently clean the substance holder (30).

BACKGROUND

A variety of brewing apparatus have been developed to combine heated water with a brewing substance such as ground coffee or tea material in order to infuse the material and produce a brewed beverage. There are many ways to combine the water with the brewing substance.

One way of brewing a beverage is to manufacture or pre-package and encapsulate the brewing substance in a filter material. The brewing substance in the filter material provides a convenient package for handling a predetermined quantity of brewing substance. The filter material provides a package or container for the brewing substance. This package allows the brewing substance to be handled prior to brewing and after brewing without complication or mess.

Such brewing substances pre-packaged in filter material are referred to as “pods” or “sachets.” Pods can be compressed while packaging in the filter material or left in a generally uncompressed condition. Pods are typically circular shaped and have a somewhat flattened configuration. Thus, pods often are provided in the shape of a disc or puck. Pods generally range in a size from approximately 45 mm to 60 mm and contain approximately 9-11 grams of brewing substance. The typical pod is used to produce approximately 8 ounces of brewed beverage. As a result, pods are generally used in conjunction with single-serve brewers (i.e., one or two cup brewers) rather than the larger, multi-serve brewers.

Although convenient, pod use in single-serve brewers may be less desirable in some situations. For example, because the pods are prepackaged by a pod manufacturer, the selection of brewing substances is limited to the pod manufacturer's selection. As a result, a consumer or user may not be able to use his/her favorite brewing substance when utilizing a prepackaged pod. Similarly, because the pods are prepackaged, varying the strength of the resultant beverage may be accomplished by increasing or decreasing the amount of brewing water delivered to the brewing substance or the pattern of delivering water to the brewing substances.

Uniform flavor extraction from the brewing material may be more difficult to achieve with a pod. Unlike open filter brewer designs which use a cone or “cup cake” filter paper brewing substance in a pod is confined within the pod and generally is not free to agitate in the brewing liquid. Instead, the brewing liquid tends to pass directly from the top of the pod to the bottom of the pod, collecting solubles as it passes through. This vertical flow pattern through the pod may result in some areas of the brewing substance being over extracted and other areas being under extracted. Accordingly, the flavor of the resulting beverage may be affected due to the non-uniform extraction of solubles, particles and other flavor characteristics from the particles of brewing substance.

In some instances, access to or availability of prepackaged pods is limited due, in part, to their proprietary nature (i.e., certain prepackaged pods are suitable for use in a particular brewer) and their associated limited distribution. For example, some brands of prepackaged pods may only be purchased from high-end specialty stores or mail/Internet ordering.

It would be desirable to provide an apparatus and method for containment of the brewing substance used in a brewer.

It would be desirable to provide the ability to allow a user to select the brewing substance used in a brewer.

It would be desirable to provide an ability to adjust the quantity of brewing substance used in a brewer.

DETAILED DESCRIPTION

While the present disclosure may be susceptible to embodiment in different forms, there is shown in the drawings, and will be described herein in detail, one or more embodiments with the understanding that the present description is to be considered an exemplification of the principles of the disclosure and is not intended to be exhaustive or to limit the disclosure to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings.

In general, a pod assembly or infusion container for use in a brewer is disclosed. The pod assembly may be provided in one of many suitable configurations adapted to enable substantial containment of a brewing substance while at the same time, allowing brewing substance selection and accommodating varying amounts of the selected brewing substance. Although described for use in a single-serving single brewer, it is contemplated that the pod assembly described herein may also be utilized with other types of brewing devices, for example, with a multiple cup brewer, espresso brewer, or a French-press or plunger-type beverage maker.

By way of background, and not limitation, as shown inFIG. 1, a single-serving brewer20includes a body22, a base24and an upper portion26. The upper portion26is configured to be positioned above a container such as a cup28for dispensing the brewed beverage into the cup28. It should be noted that many different configurations of the single-serving brewers20can be utilized in conjunction with the various embodiments of the infusion container described in this disclosure. For example, in addition to the single-server brewer manufactured by Bunn-O-Matic Corporation and described herein, single-serving brewers manufactured by Black & Decker, Krups, Home Café, Hamilton Beach, Mr. Coffee, Melitta, Senseo, Flavia, Keurig and Nespresso can be utilized in conjunction with the infusion containers. All of the embodiments disclosed can be modified and/ or sized and dimensioned to fit or otherwise work with other brewers, which one of skill in the art could accomplish without undue experimentation.

Terms including beverage, beverage making and brewing as used herein are intended to be broadly defined as including but not limited to the brewing of coffee, tea, and any other brewed beverage. This broad interpretation is also intended to include, but is not limited to any process of infusing, steeping, reconstituting, diluting, dissolving, saturating or passing a liquid through or otherwise mixing or combining a beverage substance with a liquid such as water without a limitation to the temperature of such liquid unless specified. This broad interpretation is also intended to include, but is not limited to beverage substances such as ground coffee, tea, herbs, roots, liquid beverage concentrate, powdered beverage concentrate, freeze dried coffee or other beverage concentrates, to obtain a desired beverage or other food.

While an embodiment of an infusion container or pod assembly is described herein, it is contemplated that other forms of infusion container, pod assembly or other beverage brewing substance container that substantially contains the brewing substance may be used. It is further contemplated that the present pod assembly could utilize other brewing substances and/or concentrates such as, but not limited to, freeze dried concentrates, gel, liquid, powder, gas, vapor or any other form or combination of substance or concentrate which will operate with the disclosed infusion container as well as equivalents thereof and any modifications which might be required to modify the infusion container to be used with such other substances, if necessary.

As shown inFIG. 1, an upper portion26of the single-serving brewer20, includes a holder30attached to a mounting portion32of the upper portion26. The holder30in this embodiment has a drawer-like configuration to retain a volume of brewing substance, such as an infusion container disclosed herein, in a predetermined position. The specific embodiment of the brewer is provided for illustration. Use of the disclosed structures and methods with other brewers in addition to the specific embodiment shown is within the scope of this disclosure.

FIG. 2shows a section of the upper portion26of the single-serving brewer20, taken along cross-sectional line2-2inFIG. 1. With reference toFIG. 2, the holder30includes a wall33which defines a cavity34therein. The wall33defines an upper rim36defining an entry opening38. While a holder30as described herein is shown as having a drawer-like configuration, it is contemplated that a variety of suitably configured holders may be used to define or retain the infusion container described herein. For example, a variety of brewing devices as mentioned above might include a clam shell type of pod holder, as well as an espresso-type beverage holder. It is envisioned that the infusion container of the present disclosure may be configured to accommodate these various brewing apparatus.

In addition, the holder30is configured with a floor70positioned in a lower portion of the holder30bounded by the wall33. Walls or ribs72positioned relative to the floor70enable pooling and mixing of the brewing beverage prior to dispensing into the cup28. A drain passage74formed in a lower portion of the floor70communicating with the cavity34facilitates the draining of brewed beverage from the cavity34.

A support structure73, adapted to retain the customized pod above the floor70of the holder30, is provided overlying the ribs72. Although preferably configured as a liquid permeable material such as an open mesh structure using woven metal or non-metallic strands, other configurations of the support structure73having other materials such as woven and non-woven materials are contemplated by this disclosure. The support structure73may be either fixedly attached or removably attached to an inside surface of the holder30. It should be noted that the holder30may be configured with a support structure73which does not have mesh. This will become apparent as further disclosure is provided in this document. There are embodiments of the infusion containers which include structure for selective filling with a brewing substance, such that the infusion container can be placed on a support structure73without the need for open mesh or other filtering type of structures. In this regard, the filtering will occur in the infusion container as opposed to the support structure. As such, embodiments of the support structure73without the mesh or other filtering type of structures is included within the scope of this application.

When the holder30containing the pod is inserted into the upper portion26, it engages with the mounting portion32. As illustrated, the mounting portion32includes one or more ramped, or inclined, surfaces with flat surfaces disposed therebetween, sized to receive the wall33when the holder30is inserted into the upper portion26. Additionally, the mounting portion32may include a release assembly60to selectively retain the holder30and ensure proper positioning of the infusion container during the brewing process.

The embodiment shown inFIGS. 4-7shows an infusion container or pod assembly702which includes a cover704and an insert or base735. The base735as shown is removable fro the holder. However, the base could be integrally formed, such as by molding or forming, in the bottom of the holder and not be removable from the holder. As shown inFIG. 7and as further illustrated inFIG. 8, the base includes a blade739and a protruding end791which extends beyond a rim93of a drain74to retain the insert735in the holder30. As noted in further detail below, the blade739tends to provide a columnating or laminating flow of the beverage passing through the drain.

With further reference toFIG. 7, the insert735defines a floor or base and the cover704is positioned over the insert in the cavity34. The cover704and insert735define a cavity706or brewing substance space for retaining brewing substance. Brewing substance filter material is not shown inFIG. 7in the interest of clearly showing the structures therein. However, it is envisioned that the user can provide a desired quantity of brewing substance placed in the cavity706. In this regard, the cavity706may be loosely filled or compacted when filled with brewing substance. If the user wishes to provide a large charge of brewing substance in the cavity706, the brewing substance is placed on an upper portion or top portion of the base735in the cavity706. The cover704is then placed over the cavity and pressed into the quantity of brewing substance. Placing the cover704over the brewing substance may tend to compact the brewing substance if the quantity of brewing substance is sufficient to extend above the upper portion or rim40of the holder30.

Water flows from the outside of the cover704by way of a spray head40positioned thereabove. Water dispensed by the spray head flows from the topside of the cover704and through a mesh or foraminous portion712of the cover704flowing into the brewing substance retained in the cavity706. Passages714provided through the insert735allowing beverage, such as coffee, which is extracted from the brewing substance by the water flow there through. The drain passage74defined by a drain wall73provides a path through which the beverage brewed in the cavity is allowed to drain and, as a result, be dispensed from the brewer. The insert735is adapted to retain the brewing substance above a floor of70of the pod holder30. In this regard, the uncontained brewing substance can be placed directly into the cavity on top of the insert735with the cover704placed over the brewing substance. The insert or base735, cavity34in the holder and the cover704define an infusion container702in this embodiment.

The cover704includes a rim portion720which retains the liquid permeable, foraminous or materials712therein. Mesh material can be attached to the frame using a variety of methods and structures, including, by way of example but not limitation, welding, adhesives, rolling, overmolding or any other way and means to retain the mesh on the rim.

As shown in the figures, a bail or handle732is provided on the cover704attached generally to the rim. While a variety of handles may be used, a pivotable bail or handle is shown. A finger grip or nail nick700is shown formed in the rim720. This allows a user to grip a portion of the handle732and raise it for removal from the holder30. The bail pivots down into a corresponding recess701formed around a corresponding portion of the rim720to receive the bail. In this regard, the bail can be lifted to remove the cover704from the holder30and placed in the recess701when the cover704is inserted into the holder30. This allows the bail to be recessed or placed at a level which is generally flush with a top surface of the cover704so as to not interfere with the brewing process. The handle732pivots at pivot joints703which are defined by end portions705of the handle extending through corresponding openings706formed the recess701on the rim720.

In use, the holder30is removed from the brewer20. The base735is placed in the cavity706with the blade739extending through the drain74and the end791extending beyond an edge of the drain. With the base735retained in the cavity706of the holder30coffee or other brewing substances may be placed on top of the base735. Once a desired or predetermined quantity of brewing substance is placed in the cavity706above the base735the cover704is placed in the cavity706. After the cover704has been positioned over the brewing substance the cover704may need to be pressed over the brewing substance so as to make the top surface of the cover generally flush with the corresponding top surface of the holder30. When the user has positioned the cover704in the desired position, the bail or handle732can be lowered into the recess701.

The holder30including the assembly702is then placed into the brewer20for brewing. During the brewing process water enters the upper portion of the cover704to flow through the liquid permeable portion712in the openings and into the brewing substance contained under the cover704in the brewing substance cavity. The brewing substance is infused by the water and a beverage flows through the base. Beverage flowing through the base flows onto the drain74for dispensing from the brewer.

When the user has completed the brewing process the holder30is removed from the brewer20. The user places his finger in the finger grip700to grip the handle732. As the user pulls up on the handle732the handle pivots at the pivot joint703. After an appropriate amount of force is applied, the user will be able to disengage the cover704from the cavity706. The user then can empty the spent coffee or other brewing substance from the cavity706by inverting it over a disposal container. The cover704and holder30can be washed either manually or in a dishwasher. When cleaned, the holder30and corresponding components735,704can be prepared for the next use.

As shown inFIG. 8, another embodiment of a reusable container or infusion container402used with a pod holder30is defined by an insert35which defines a base and a cover404which is positionable over the insert35. The cover404and insert35define a cavity406or space when positioned in the holder30for retaining the brewing substance408. Water410flows from the outside of the cover404and through a mesh or foraminous portion412of the cover404flowing into the brewing substance408. Passages414are provided through the insert35allowing coffee beverage which is extracted from the brewing substance408by the water410to flow downwardly there through. A drain74defined by a drain wall73provides a path through which beverage brewed in the cavity406is allowed to drain and, as a result, be dispensed from the brewer. The pod holder insert35is adapted to retain the brewing substance408above a floor70of the pod holder30. A series of braces81are provided on an underside83of the insert35. Further reference to and details relating to structure and function of the insert35is provided in the related application U.S. Provisional Application No. 60/575,235 which is incorporated herein by reference in its entirety.

As shown inFIG. 8, the insert35includes a protruding end91and a blade39. The blade39generally extends through the drain passage74with the protruding end91extending beyond a rim93of the drain74to retain the insert35and the holder30. The blade tends to provide a columnating or laminating flow of the beverage passing through the drain.

The cover404includes a rim portion420which retains the foraminous or mesh material412therein. The mesh material can be attached to the frame using a variety of methods and structures, including, by way of example but not limitation: welding, adhesives, rolling, overmolding or any other way and means to retain the mesh on the rim. With reference toFIG. 8, a seal422is carried on the rim420for engaging in upper rim36of a wall33of the holder30. The seal helps to reduce or prevent the flow of liquid out of the cavity and therefore tends to direct the flow of beverage brewed in the cavity downwardly towards the insert35. As noted above, the insert35has a foraminous area, thereby allowing the passage of brewed beverage there through. A similar seal424is provided on the insert so as to engage a corresponding surface426of the wall33. This seal424also helps reduce or prevent the passage of liquid or brewing substance around the insert. Rather, the brewed beverage must flow through the filter material428carried on the insert35. Generally, the filter material428is supported by a structure430attached to the blade39. The filter material428prevents the passage of undesirable particles of the brewing substance into the brewed beverage which is dispensed from the nozzle74.

As shown inFIGS. 8,9and10, the cover404includes a handle432attached to the rim420. The handle432is generally of a low profile design thereby allowing for a gripping structure, yet not intruding or interfering with the operation of the holder30when inserted into the brewer20. Various forms of the handle may be provided such as one which is integrally formed with the rim420. Additionally, the handle432provides additional structure to reinforce the overall structure of the cover404.

The insert35may include, by way of example but not limitation, the mesh and structure as shown herein or may be formed of the mesh and structure as shown in U.S. Pat. No. 5,292,437, issued to the assignee of the present invention. The disclosure in teachings of U.S. Pat. No. 5,292,437 is incorporated herein by reference in its entirety.

In use, the reusable container structures including the cover404and the insert35can be provided with a brewer as shown inFIG. 1. While the structures404,35can be the primary devices which are used in the brewing process, they can be provided as an accessory as well. In this regard, the brewer can be provided for use with prepackaged pods. Such pods may be supported by the insert35as shown herein or as shown in the related U.S. Provisional Application No. 60/575,235. All of the variations of the infusion container disclosed herein are to be broadly interpreted. Additionally, all of the variations of the infusion container may be used as a retrofit or accessory kit with a brewer. The reusable container structures404,35allow a user increased choices in preparing coffee by allowing the user to install the insert35, place a desired quantity of brewing substance408into the cavity and then placing the cover404there over. The user can use a relatively large or small charge of coffee and can control the type of grind and coffee used in the brewer. Additionally, there may be economic benefits to using loose coffee instead of prepackaged single serving pods. The cover404can be provided in a hinged configuration such that the hinge is attached to the holder30and the cover404. This would allow the hinged structure to be retained on the holder30. The hinged structure may be configured such that it pivots out of the way for use with pods and pivots into place for use with loose coffee.

As further shown inFIG. 11, a pod assembly or infusion container40is shown. The pod assembly40as shown inFIG. 11is elevated from or exploded from the cavity34of the holder30. This positioning of the pod assembly40relative to the holder30is provided for clarity. In use, the pod assembly is positioned in the cavity generally with a top surface42of the pod assembly40positioned relative to and generally flush with a corresponding top surface44of the holder30. As described herein and the other corresponding applications incorporated herein by reference, a water system delivers water to the holder30such that water is infused through the top portion42of the pod assembly40to infuse beverage brewing substance retained within the pod assembly40. The brewed beverage passes through the brewing substance retained in the pod assembly and is dispensed through a dispensing hole46generally in the bottom of the cavity34of the holder30.

With further reference toFIGS. 12-16, the pod assembly or infusion container generally includes a first portion50and second portion52. The first portion50and second portion52define a cavity54there between. Brewing substance is retained in the cavity for brewing within the holder30. A first face56of the first portion50is provided with at least one opening58. The openings58are covered with a foraminous or otherwise water permeable material59. While the term mesh is used herein for convenience, the term is intended to be broadly interpreted to include any type of material, substance, or structure which retains the brewing substance but allows water and brewed beverage to pass therethrough. For example, a woven mesh or non-woven fabric made of plastic, metal or any other suitable material may be used. The mesh material may be of any suitable construction having an openness or porosity, compatible with the type of brewing substance used. Generally, the first portion50is formed with the mesh59retained therein either by attaching the mesh59portion in segments, sheets or otherwise over molding or attaching the mesh59to the first portion50. While the term mesh is used, it is contemplated that any other suitable foraminous, water permeable or otherwise open material may be used to allow water to pass from the upper surface42of the first portion50into the cavity54. Additionally, the present disclosure is intended to include all variations of infusion containers that have at least two pieces including a first portion and a second portion and in which the first portion and second portion define a cavity therebetween for holding a brewing substance therein. The first and second portions may or may not be engageable. The infusion containers which are engageable are intended to include all forms of engaging the two portions.

Likewise, the second portion52includes corresponding openings60which are covered by a suitable mesh material61. The mesh61in the second portion52may be attached by any suitable method including attaching portions in each opening60, sheets, over molding or any other way in which the mesh61might be attached to the second portion52. The mesh61in the second portion52may be the same as the first portion50or may be any suitably different opening dimension or mesh dimension to achieve a desirable result. In this regard, it may be desirable to provide a more open mesh in the upper portion to allow water to flood into the cavity for brewing and provide a tighter or smaller mesh in the second portion52to trap particles and other materials which might not be desirable for dispensing into a cup28.

In use, a user will disengage the first portion50from the second portion52to separate the portions50,52to provide access to the cavity54. The user then places a desired quantity of brewing substance, such as coffee, within the cavity of the second portion52in preparation for infusing the substance with water to produce a brewed beverage. The user then places the first portion50over the second portion52and engages the two portions to hold the two portions50,52in engagement and to prevent spilling of the brewing substance retained therein. The user then places the assembled pod assembly40into the cavity34of the holder30for brewing. The holder30is placed into the brewer for brewing a beverage. At the completion of a beverage brewing cycle, the user removes the pod assembly40from the holder30and disengages the first portion50from the second portion52. The moist brewing substance in the cavity54can then be dislodged from the corresponding first and second portions50,52for disposal. The interior surfaces of the first portion50and second portion52facility easy rinsing and cleaning. It may be desirable to fabricate the assembly40of suitable materials to facilitate and be durable for repeated cleaning such as by use of a dishwashing machine or manual washing.

With further reference to the figures, the assembly40includes a grip portion62and locking portion64. The grip portion is shown on the first portion50in the form of protrusions. Any other form of gripping structure, such as suitably gripable material, such as an elastomeric material, knurled surfaces, or irregular shapes as well as any other form of gripping structure or material may be used for the grip62. As shown and described in the present disclosure, the grip portion62is provided around the circumferential area of the first portion50. This allows a user to hold the lower portion and hold the second portion52and grip the first portion50to disengage the locking structure64. It is intended that the grip portion be broadly interpreted to extend over all or part of the first portion50as well as include such structures or materials on the section portion52, in addition to or in place of the grip portion on the first portion50.

The second portion52may also include a holding or traction portion68. The holding or traction portion68as shown in the illustrations as protruding ribs. As will described in greater detail below, these ribs68also elevate the lower portion52off of the base or floor70of the holder30cavity34to allow brewed beverages to flow through the mesh61in the second portion52. When disengaging the first portion50from the second portion52, the user grips the gripping portion62and holds the second portion52. The extending ribs68provide traction for resistance to prevent slipping of the second portion relative to the user's hand. The traction portion68may also take a variety of embodiments such as other shapes, structures or materials. It is envisioned that any form of traction structure may be used so as to help facilitate disengagement of the first and second portions. It should also be noted that actual structures may not be needed due to the shapes and portions of the pod assembly40. In other words, the shape and structure of the second portion52may be such that it provides suitable traction to resist rotation when disengaging the first portion50from the second portion52.

With reference toFIG. 14, it can be seen that the second portion52has an outer perimeter generally defined by a rim72. The first portion50has a corresponding generally planar surface74, relative to the rim72. In this regard, the user can fill the second portion52with a suitable brewing substance and then strike or level the brewing substance in the second portion52relative to and across the rim72. The view inFIG. 14is inverted for consistency with the section line14-14inFIG. 13. Alternatively, the user may leave a slightly rounded surface relative to the rim72. In this regard, the slight overfill or “rounding” of the brewing substance in the second portion52may increase the quantity of brewing substance in the pod assembly40. In this situation, when the user applies the first portion50, the brewing substance retained in the cavity54may be slightly compressed by engagement of the first portion50and the second portion52. This may be desirable, depending on the user's preference. Overfilling and compressing the brewing substance may result in producing a different flavor characteristic or other characteristic of the coffee as might be desired by a particular user. Regardless of the specific details of the resulting beverage, the user will be able to exercise some degree of control in designing and repeating their desired beverage characteristics depending on how they fill the pod assembly.

As shown in the figures, the locking structure64includes an extending finger80and a corresponding engageable lug82. The lugs and fingers may be carried on either structure50,52for suitable engagement. The finger80shown on the first portion50includes an extending barb86which engages the corresponding lug82. Generally, it is preferable to position the locking structures64outside of the cavity54to minimize the amount of brewing substance which might otherwise interfere with the operation of the locking structure.

As shown, three spaced apart locking structures64are spaced around the perimeter of the first and second portions50,52. While more or fewer locking structures may be provided, the illustration shows the three locking structures64. These spaced apart structures provide some degree of balance when engaging the first and second portions50,52.

In use, when engaging the first portion50on the second portion52, the user aligns the fingers with a corresponding recess88proximate to and in front of the corresponding lug82. Once the finger80is positioned in the recess88, the user positions the first and second portions80,82together to close the cavity54. In the closed position, the user can then rotate the first portion50relative to the second portion52to engage the barbs86underneath the corresponding lugs82and bring the fingers80and lugs82into engagement to retain the portions50,52in engagement.

As an alternative embodiment, the first and second portions50,52may be provided with a living or mechanical or otherwise assembled hinge and a corresponding locking structure. While the locking structure as described above with the rotational engagement of the finger and lug may not be applicable in this situation, it is envisioned that a similar snap feature may be used as an equivalent locking structure. For example, the finger and barb may be formed of a suitably flexible material or sliding engagement to allow displacement of the finger when engaging the barb with the corresponding lug. Additionally, this embodiment of the spring biased or snap finger and lug construction may be used in structures which do not have a hinge component. However, it is envisioned that there will be some form of locating structure to facilitate locating an engagement of the first portion and second portion to align the first and second portions prior to engaging the locking structure.

In use, the user separates the first portion and second portion50,52to place brewing substance in the cavity54. If necessary, the user may then strike or compress the brewing substance in the cavity54. The user brings the first portion into alignment with the second portion52prior to engagement. The user then engages the lock structures64to retain the first and second portions50,52in engagement.

The assembled pod assembly40is placed into the cavity34of the holder30. The holder30is placed into the brewer and the brew cycle is activated by the user. Heated water enters the brewing area and flows through the mesh59covering the openings58on the first portion50. Water flows through the mesh59and into the brewing substance whereupon it infuses the brewing substance for extracting a brewed beverage. Brewed beverage flows through the brewing substance and out through the mesh61covering the openings60in the second portion52. As the lower portion or base includes the ribs68, coffee or beverage flowing through the mesh61flow through the void90, defined between neighboring ribs68, the corresponding surface of the second portion and the floor or bottom70of the cavity34to and through the hole46into the cup28.

At the conclusion of the brewing cycle, the pod assembly40can be removed from the holder30and opened to remove the spent brewing substance. The grips62on the assembly40facilitate removal from the holder30even if the brewing substance is relatively warm. This allows a user who wants to repeatably brew beverage from the brewer to do so without being sensitive to warm brewing substance.

The first portion50is disengaged from the second portion52by rotating the first portion relative to the second portion. As described above, other configurations for engaging and disengaging the pod assembly can be developed based on the teachings of the present disclosure. These various embodiments are included within the scope of the disclosure. The user can then empty the spent brewing substance and rinse the interior surfaces of the cavity54for reloading with brewing substance. Additionally, the first and second portions50,52may be fabricated of a dishwasher safe material to allow them to be placed in the dishwasher for cleaning and sanitizing for subsequent use.

It is envisioned that the mesh59in the first portion50and mesh61in the second portion52may be sized and dimensioned of a suitable material for use with a desired brewing substance. In this regard, as described above, the mesh materials59,61in the first and second portions50,52may be the same or may be formed of different materials or different sizes. In this regard, a more open or larger mesh size may be used in the upper portion50and smaller or tighter mesh portion may be used in the lower portion. Additionally, it is envisioned that mesh may not be used but a foraminous surface, non-woven fabric or any other suitable structure that generally retains larger particle, such as brewing substance and allows liquids such as water and brewed coffee to pass there through.

It is also envisioned that other configurations of mesh may be used in the first and second portions for use with other brewing substances such as herbs, teas or any other substance that might be used. In other words, the mesh portions can be configured to provide a matched flow of water into and beverage out of the cavity depending on the brewing substance used. For example, if it is desirable to allow a large quantity of water to rush into the cavity54, depending on the brewing substance and restrict the outflow, the inlet mesh can be relatively larger or more porous, while the outlet mesh can be relatively smaller or less porous. Also, by way of example but not limitation, a larger mesh may be used on both ends to produce a lighter beverage, such that the contact time of the water and brewing substance is reduced allowing less contact and lighter beverage production. It is also envisioned that the openings58,60which are covered by the mesh may be devised or otherwise shaped in a variety of configurations and geometries to produce various effect on the brewing process and achieve various results. The various configurations and geometries are within the scope of the present disclosure and incorporated herein.

FIGS. 17 and 18show another embodiment of a reusable infusion container502. This embodiment of the reusable infusion container includes a two part construction, including a cover504and a base535. The base may include a flange or seal524for engaging the inside surface426of the wall33. Similarly, a seal or flange522may be provided on the cover504to engage the rim36of the wall33. The cover and base504,535define a cavity506therein for retaining brewing substance. Brewing substance is placed in the cavity506and the cover504is placed there over. The cavity506can be partially filled or filled to the rim, such that positioning of the cover504there over strikes or levels the brewing substance retained in the cavity506. The user can determine the degree of compaction of brewing substance in the cavity506. Mesh material512is provided on the cover504. A similar mesh structure or material such as is used on the insert35as shown inFIG. 8is provided in the base535. Mesh or permeable material is not shown inFIG. 18in the inertest of clarity.

As also shown inFIG. 17, the structure of the base or cover535,504can be configured with a ratcheting or other engaging structure shown generally herein as reference number560. The threads allow the cover504to be engaged with a portion of the base535in a positive manner. The ratchet points on the base535engage corresponding ratchet points on the cover504. The threads and ratchet points provide positive engagement as well as a sensory feedback to indicate the degree of engagement or compaction of the brewing substance retained between the cover504and base535. For example, the base535can be filled with a brewing substance which, generally is placed in a loose, uncompacted state. Placement of the cover504over the base facilitates engagement of the cooperative threads on the corresponding portions of the cover and base. Rotation of the cover relative to the base further engages the threads whereupon the ratchet structures564are encountered. By way of example but not limitation, first engagement or clicking of a first ratchet structure indicates compaction level1. Further rotation and clicking or engagement of the ratchet structures indicates further compaction. As such, a user can repeatably control dose by using a measuring spoon to place a desired quantity of brewing substance within the base535. The user can also repeatedly control the degree of compaction of the brewing substance by use of the engaging structures560. As such, these features of the container502adds greater control in the use of the reusable container502.

The reusable container502as shown inFIGS. 17 and 18operates in a similar principle to that as shown in the previous figures. The container may be provided as an accessory to the brewer20or as an additional purchase part or retrofit kit. The container502can be sized and dimensioned for use with any variety of brewers which might otherwise use single serving disposable pods. The reusable container allows greater control in the brewing of beverages, possible cost savings as well as positive environmental effects by not placing additional materials which might otherwise be provided in a reusable form.

As shown inFIG. 18, the container502is placed in the cavity holder. The holder can then be installed in the brewer for subsequent brewing operations. Once the brewing operation has been completed the drawer30is removed from the brewer20and the holder502can be removed from the holder30. The cover504is separated from the base535for rinsing or otherwise removing the spent brewing substance408. The cover504and base535may be formed of any suitable material including plastics, metallic materials, glass, composite materials, suitable flexible materials such as sanitation-approved cooking silicones and other similar materials as well as other materials not here listed. The general concept is to provide a two part reusable container which can be filled with the brewing substance and then placed in the holder30.

In use, the container502is filled with a brewing substance to a desired level and compaction. The container502is placed in the holder30whereupon the holder is engaged with the brewer20. During a brewing cycle, brew water flows through the upper mesh or other foraminous structure512and through the brewing substance retained in the container502. Brewed beverage flows outwardly from an open or otherwise foraminous area of the base535and through the holder30for subsequent dispensing into a container such as a cup28. After use, the container502is removed from the holder30for subsequent removable of spent brewing substance and, if desirable, cleaning of the holder parts504,535.

A further embodiment of a reusable infusion container602is shown inFIG. 19.FIG. 19shows the reusable container602, having a base635and a cover604. In this embodiment, the cover604is attached to the base635by a hinge650. Additionally, a closure or clasp structure652is retained on either the cover604or base635. A rim portion620retains a structure or other foraminous material612. In the embodiment as shown asFIG. 19, the mesh material is formed in a generally arcuate or partially spherical shape so as to help define a cavity between the base635and the cover604. While the cover need not be provided with a similar arcuate structure, it should include at least a partially foraminous or otherwise mesh area612. Generally, a rim620is provided on the cover604to retain the foraminous material612there between. A seal may be provided under the rim620of the base635so as to engage the internal surfaces of the cavity of the holder30.

In use, the reusable container or infusion container602is opened by disengaging the clasp652from the rim portions of the cover604and the base635. The cover604can then be removed from the base to allow the placement of brewing substance therein. Once a desired quantity of brewing substance has been placed in the base635, a cover604is placed there over with the clasp652positioned to engage the rims620. The closed and retained container602can then be placed in the cavity of the holder30as shown inFIG. 2. The holder30can then be engaged with the brewer24commencing a brewing operation. At the end of a brewing operation, the container602can be removed from the holder30to allow opening of and cleaning of the container. Spent brewing substance can then be removed from the container and subsequent cleaning or other steps can occur to the container602. As noted above with regard to the other embodiments, the container602can be provided with the brewer20as the primary brewing substance holder or as an accessory or retrofit kit for use with this or other brewers. Of course, the container602will be sized and dimensioned for an appropriate brewer. It is possible that any of the containers disclosed herein can be sized and dimensioned such that a single reusable container can be used across a variety of single cup brewers which might otherwise use disposable single serving pod products. The infusion container as shown inFIG. 19can be placed in the cavity of the holder for brewing.

As mentioned hereinabove, the customized pod or infusion container may be configured in one of many suitable configurations adapted to enable substantial containment of a brewing substance while at the same time, allowing brewing substance selection and accommodating varying amounts of the selected brewing substance. Additionally, the customized pod may be constructed using one of many suitable materials such as a reusable synthetic or metallic material or a disposable filter paper material, to name a few.

For example, the customized pod or infusion container may be configured as a refillable infusion container constructed of a metallic material such as gold mesh and sized and dimensioned to be received in the cavity34of the holder30. In one embodiment, the refillable infusion container200includes a container portion202coupled to a removable spring loaded handle204. In another embodiment, the container portion202is provided without a handle204. The container portion202includes a first container half206having a first rim208radially disposed around the edge of the first container half206, and a second container half210having a second rim212radially disposed around the edge of the second container half210. The handle204is preferably formed by a first outer arm214and a second outer arm216pivotally mounted to a V-shaped spring loaded actuating arm218. A first end of the first outer arm214is pivotally coupled to a first end of the V-shaped spring loaded actuating arm218. Similarly, a first end of the second outer arm216is pivotally coupled to a second end of the V-shaped spring loaded actuating arm218. The first outer arm214includes a first flange220disposed proximate to the second end of the first outer arm214, and the second outer arm216includes a second flange222disposed proximate to the second end of the second outer arm216. A pivot pin224inserted through a first aperture in the first flange220and a second aperture in the second flange222pivotally couples the first outer arm214to the second outer arm216.

The second end of the first outer arm214is removably attached to a first rim portion226of the first rim208via a first bracket230mounted to the first rim portion226. Similarly, the second end of the second outer arm216is removably attached to a second rim portion228of the second rim212via a second bracket232mounted to the second rim portion228. The first rim portion226is proximate to the second rim portion228when the refillable infusion container200is biased into the closed position.

Upon compression of the V-shaped spring loaded actuating arm218, near the area of the first ends of the first and second outer arms214,216, the first and second container halves206,210are urged apart. The first rim portion226is no longer proximate to the second rim portion228. Any suitable brewing substance, in any suitable quantity may then be deposited within the container portion202(see,FIG. 19). Upon closing the first and second container halves206,210, the container portion202may be latched via a first latch240and a second latch242(not shown), and the spring loaded handle204removed. The infusion container in the form of the latched container portion202may then be placed in the cavity34(see,FIG. 20). Although removable, it is contemplated that the spring loaded handle204may be non-removable and may include a non-heat conductive material (e.g., high temperature plastic, suitable metal, or ceramic material) adapted for grasping during removal of the refillable infusion container200from the single-serving brewer20. The embodiment using the non-removable handle included sufficient gasketing and sealing around the handle to maintain the desired closure of the brewing chamber during the brewing process.

The refillable infusion container200may be constructed of any suitable metallic material including, but not limited to gold mesh, enabling suitable brewing liquid flow there through and suitable durability for repeated use and reuse. In addition, although preferably puck-shaped, the refillable infusion container200may be configured in one of any number of suitable shapes sized to fit within the cavity34, including, but not limited to, a dome shape, a spherical shape, an elliptical shape, a basket shape or a conical shape, to name a few. Further, although the removable spring loaded handle204enables access to the interior of the container portion202, other methods to access the interior of the container portion202are contemplated. For example, the first and second container halves204,206may be threadedly coupled or hingedly coupled in a clam shell fashion, thereby precluding the need for access via operation of the spring loaded handle204.

The infusion container may also be configured as a reusable container250, utilizing a resilient metallic porous material or a spring loaded metallic porous material. As illustrated byFIGS. 22 and 23, the reusable container250may be configured as a resilient “purse-shaped” reusable pod of a suitable shape and sized and dimensioned for use with a corresponding brewer. The purse-shaped pod has a slit252therein (rather than being formed by first and second container halves206,210). As illustrated, the interior of the purse-shaped reusable pod252can then be accessed by “pinching” opposing sides254and256of the resilient purse-shaped device252(see,FIGS. 22 and 23).

As mentioned above herein, the customized pod or infusion container may also be constructed using other types of porous materials such as a disposable filter paper material or other suitable disposable porous material. For example,FIG. 24is a perspective view of a disposable customized pod260constructed of a disposable filter paper material and configured in a “cup-cake” filter shape. In the illustrated example, the disposable pod260includes a cup portion262having a wall264which defines a brewing substance holding area266for holding the brewing substance, which is generally similar to larger versions of this filter configuration as used in larger brewers. However, a flap portion268can be added to the filter, coupled to a portion of a rim267defined by the wall264. Upon receiving the brewing substance in the brewing substance holding area266, the flap portion268is folded over the brewing substance holding area266. The filled, disposable customized pod260may then be placed in the cavity34for brewing. The disposable customized pod260, therefore, provides sufficient containment for the brewing substance, while at the same time, allows the user to select the type and amount of brewing substance. Although illustrated as having a flap portion268, it is contemplated that the pod260may be configured without the flap portion268. Further, it is also contemplated that the disposable customized pod260may be configured in one of any number of suitable shapes such as a cone shape, a trough shape, a pouch shape with or without a twist-top portion, etc.

The disposable customized pod may also be configured with a removable portion that is discarded after filling to reduce the amount of disposable filter paper material exposed to the brewing liquid during the brewing process. Accordingly, after the brewing substance is placed in the brewing substance holding area266but before the beverage is brewed, the removable portion that is to be discarded is removed.

For example, the disposable customized pod may be configured as a pouch with a twist-top having a removable portion. Referring toFIGS. 25 and 26, there is shown a disposable customized pod270configured as “pouch” with a twist-top272having a removable portion274. After filling with a brewing substance, the brewing substance holding area266can be manually twisted shut to contain the brewing substance via the twist-top272, and the removable segment274removed and discarded. The filled and closed customized pod270can then be placed into the cavity34for brewing. Although manually removed by the user, it is contemplated that the removable portion274may be automatically removed by a suitable device of the single-serving brewer20.

The disposable customized pod also may be configured as one of a string of detachable disposable customized pods that are adapted to be used in a customized pod making system. It is contemplated that the customized pod making system may be included in the single serving brewer20or it may be a stand-alone system. For example,FIG. 27is an exemplary string of detachable disposable customized pods300that may be utilized in conjunction with the single serving brewer ofFIG. 1.

In the illustrated example, the string of detachable disposable customized pods300includes four detachable disposable customized pods302,304,306and308, however, more or less customized pods may be included. Although the detachable disposable customized pods are illustrated as having a circular “pouch” shape, other shapes, including, but not limited to, a cone shape, a puck shape, a square shape and a basket shape, are contemplated. In one embodiment, the detachable disposable customized pods302,304,306and308may be detached, filled with a brewing substance and placed into the single serving brewer20via a manual process. In another embodiment, the detachable disposable customized pods302,304,306and308may be detached, filled with a brewing substance and placed into the automatically the single serving brewer20via an automatic process. In further embodiments, it is contemplated that one or more combinations of manual and automatic steps may be utilized to detach, fill and place the detachable disposable customized pods302,304,306and308into the single serving brewer20.

Additionally, manual or automatic closing or sealing of the filled detachable disposable customized pods302,304,306and308is contemplated. For example, upon filling the detachable disposable customized pod302with a brewing substance, a neck portion301of the detachable disposable customized pod302may be automatically cut and/or removed, and the remaining aperture sealed via heat, compression, suitable adhesive or by use of mechanical clamps or retainers.

Referring again toFIG. 2, in the installed position, the holder30is positioned with the entry opening38in position to receive the brewing liquid (e.g., water). The entry opening38and cavity34are positioned below a spray head40. Any one of the customized pods described above is held within the cavity34. During operation, the brewing liquid46provided by a water delivery system of the single-serving brewer20, enters a spray head area42defined by the spray head40. The brewing liquid46in the spray head area42then flows through holes44, through the entry opening38, and into the cavity34. Upon receipt in the cavity34, the brewing liquid46mixes with the brewing substance retained by the customized pod. The brewing liquid46, flowing through the customized pod and infusing the brewing substance contained therein, subsequently drains under pressure and gravity through the support structure73, and into open areas defined by the upstanding ribs72where the soluble portions of the brewing substance with the brewing liquid are pooled and mixed. When completed, the brewed beverage drains through a drain hole50, into the drain70for dispensing into the cup28.

In use, the beverage maker is employed with a refillable or reusable substance container as well as a selectively fillable substance container. The steps involved in this process include providing an infusion container. The infusion container is then filled with a suitable beverage making substance. The infusion container is placed in a corresponding beverage maker and employed during a brewing cycle to produce a desired beverage. At the conclusion of the brewing cycle, the infusion container can be removed and disposed of or cleansed for reuse.

Further details of the configuration and operation of the single-serving brewer20can be found in related provisional applications and subsequent non-provisional applications entitled “Apparatus, System and Method for Infusing a Pre-Packaged Pod filed Feb. 9, 2004, “Apparatus System and Method for Retaining Beverage Brewing Substance” filed Feb. 6, 2004, and “Pod Brewer Design” filed Feb. 10, 2004. Additional information relating to adjustable controlling the single-serving brewer20can be found in a related provisional application and subsequently filed non-provisional applications entitled “Adjustable Volume Brewer” filed Nov. 7, 2003, U.S. Provisional Application No. 60/518,039. Additional information related to a spray head system and method for delivering water to the brewing assembly of the single-serving brewer20can be found in U.S. Provisional Application and subsequently filed non-provisional application entitled “Water Delivery System, Method and Apparatus” filed Nov. 7, 2003, U.S. Provisional Application No. 60/518,411. Additional information related to beverage making apparatus which uses loose coffee and related devices and methods of use can be found in U.S. Provisional Application and subsequently filed non-provisional application entitled “A Beverage Making Apparatus and Method Using Loose Beverage Substances” filed Apr. 2, 2004, U.S. Provisional Application No. 60/560,033. Information about a pod holder with a removable insert can be found in U.S. Provisional Application and subsequently filed non-provisional application entitled “Pod Holder with Removable Insert” filed May 28, 2004, U.S. Provisional Application No. 60/575,235. Information about a beverage making apparatus which uses loose coffee and related devices and methods of use can be found in US Provisional Application entitled “A Beverage Making Apparatus and Method Using Loose Beverage Substance” filed Sep. 1, 2004, U.S. Provisional Application No. 60/606,233. Each of the above-referenced applications and the materials set forth therein is incorporated herein by reference in its entirety.

While embodiments have been illustrated and described in the drawings and foregoing description, such illustrations and descriptions are considered to be exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. The applicants have provided description and figures which are intended as illustrations of embodiments of the disclosure, and are not intended to be construed as containing or implying limitation of the disclosure to those embodiments. There are a plurality of advantages of the present disclosure arising from various features set forth in the description. It will be noted that alternative embodiments of the disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those of ordinary skill in the art may readily devise their own implementations of the disclosure and associated methods, without undue experimentation, that incorporate one or more of the features of the disclosure and fall within the spirit and scope of the present disclosure.