Abstract:
The present description includes containers having an improved puncture design that can be punctured without substantial deformation of the container. Such containers are particularly suitable for use in preparing beverages using automatic machines, particularly those used for preparation of single serve beverages. Also provided are thermoplastic materials having improved punctureability for use in containers, containers for preparation of a beverage, and methods for preparing a beverage using such containers.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/719,136 filed on Oct. 26, 2012, the disclosure of which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    The present application relates generally to the field of containers for preparation of beverages, especially coffee and tea. These containers commonly are referred to as cartridges, cups, capsules, or pods, and are particularly suitable for use in the preparation of a single-serve beverage. 
         [0003]    In recent years, single-serve beverage machines have become popular in homes and businesses as a quick and convenient manner of brewing beverages. These machines generally brew coffee, tea, or other hot beverages through polymer containers that may have integral filters and are filled with coffee grinds, tea leaves, or other soluble products. Upon brewing of these products, the container may be easily discarded so that the machine is available for preparation of subsequent beverages. These containers thereby enable users to customize their beverages and also enjoy freshly brewed beverages quickly and easily. 
         [0004]    Although convenient, existing containers used for the preparation of beverages have numerous drawbacks. For example, many commercially available containers are prepared using materials that are less easily recycled. This is due at least in part due to the structural characteristics that are required for these containers. For example, the containers must be sufficiently strong to permit puncturing of the base of the container without substantial deformation of the container. Thus, there exists a need for a structure that permits use of more easily recycled materials while still having sufficient structural integrity. 
       SUMMARY OF THE DESCRIPTION 
       [0005]    Embodiments of the present description address the above-described needs by providing a container including a substantially circular and horizontally extending base, a frustoconically shaped wall extending therefrom and defining a cavity therein, and a stacking shoulder which intersects and extends laterally from the wall. The base includes an outer annular peripheral support structure including a plurality of recesses therein. The base optionally may include an inner annular support structure that together with the outer annular peripheral support structure defines a continuous puncture region sized and shaped to permit a puncture therein without interference and without substantial deformation of the container. 
         [0006]    Also provided in embodiments herein are containers for preparation of a beverage using the above-described container and methods for preparing a beverage using such containers. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a side view of an embodiment of a container according to a first embodiment. 
           [0008]      FIG. 2  is a bottom view the container illustrated in  FIG. 1 . 
           [0009]      FIG. 3  is a top view of the container illustrated in  FIG. 1 . 
           [0010]      FIG. 4  is a forward lower perspective view of the container illustrated in  FIG. 1 . 
           [0011]      FIG. 5  is a forward lower perspective view of a container according to a second embodiment. 
           [0012]      FIG. 6A  and  FIG. 6B  are schematic illustrations of a design that may be applied to the inner surface of a cup base according to embodiments. 
           [0013]      FIG. 7A  and  FIG. 7B  are schematic illustrations defining various parameters of a container according to embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    Embodiments of the present application address the above-described needs by providing a container for preparation of a beverage. As used herein, the term “container” is synonymous with cartridges, cups, capsules, pods, and the like, that may be used in the preparation of a beverage. 
         [0015]    The container generally comprises a cup-shaped container with a base and a frustoconically shaped sidewall defining an opening. In an embodiment, the base includes an outer annular peripheral support structure comprising a plurality of recesses and optionally an inner support structure. A continuous puncture region disposed between the outer annular peripheral support structure and optional inner support structure is configured such to permit the container base to be punctured in the continuous puncture region during the preparation of the beverage. 
         [0016]    An exemplary embodiment of a container  10  is further illustrated in  FIGS. 1-4 . The container  10  comprises the base  12  and the frustoconically shaped sidewall  14  defining an opening  16 . The sidewall  14  may include a radially outwardly protruding lip  18  surrounding the opening  16 . In one aspect, the radially outwardly protruding lip  18  further comprises a stacking shoulder  19  that intersects and extends laterally from the sidewall  14 . 
         [0017]    The base  12  includes an outer peripheral support structure  20 , an inner support structure  22 , and a continuous puncture region  24  therebetween. In embodiments, the outer peripheral support structure  20  is an annular shape having a plurality of recesses  26  similar in appearance to an inverted parapet (i.e., castle-like structure of a battlement or crenellation). In embodiments, the inner support structure  22  is an annular shape or a circular shape. 
         [0018]    The continuous puncture region between the outer peripheral support structure  20  and inner support structure  22  is configured to permit the puncture of the container base at any position in the continuous puncture region  24  during preparation of the beverage. Although the presently described embodiment of outer peripheral support structure  20  or inner support structure  22  are annular shapes, other shapes also may be used (e.g., elliptical, triangular, square, hexagonal, heptagonal, octagonal, and the like), provided the structure does not interfere with puncturing of the base in the continuous puncture region  24 . Those skilled in the art will appreciate, however, that the concentric annular shaped support structures are particularly suitable for defining a continuous puncture region that may be punctured at any position, thereby allowing the container to be positioned within the beverage machine without regard for the position of the puncture region. 
         [0019]    In embodiments, the outer peripheral support structure may comprise more than one annular shape having a plurality of recesses as illustrated in  FIG. 5 . For example, the outer peripheral support structure  122  may comprise a first outer annular shape  123 ′ having a plurality of recesses  126  and a second outer annular shape  123 ″ having a plurality of recesses  126  positioned inside the first outer annular shape  123 ′ and outside the continuous puncture region. The plurality recesses of the  126  of the first outer annular shape  123 ′ and second outer annular shape  123 ″ may be offset from each other. In embodiments, the first outer peripheral support structure and the second outer peripheral support structure have substantially the same dimensions. Those skilled in the art will appreciate, however, that the dimensions of the first outer peripheral support structure and second outer peripheral support structure may be different (i.e., different widths, recess sizes, number of recesses, and the like). 
         [0020]    In embodiments, the container further comprises other features to facilitate the punctureability of the base. For example, in an embodiment the container may include a feature in the inner surface of the base of the container. The feature may be effective to weaken the material of the base during its puncture without sacrificing its strength, for example, by providing stress concentrators. Two exemplary embodiments of the feature are illustrated in  FIGS. 6A and 6B , which illustrate the designs that may be imprinted in the inner surface of the base of the container. Other designs also may be used. 
         [0021]    In an embodiment, the container may be further characterized by the following mathematical relationship: 
         [0000]        h= ( R   1   −R )·tan (90−Φ)
 
         [0000]    wherein h is the height of the container from the base  12  to the stacking shoulder  19 , R 1  is the inner radius of the container at the stacking shoulder  19 , R is the radius of the base  12  including the outer peripheral support structure  20 , and Φ is the approach angle. 
         [0022]    The container can further be characterized by the dimensions of the base features: r is the radius of the base  12  excluding the outer peripheral support structure  20 , r 1  is the inner radius of the inner support structure  22  comprising an annular shape, r 2  is the outer radius of the inner support structure  22 , w o  is the width of the outer peripheral support structure  20 , d is the width of the continuous puncture region  24  of the base  12 , w i  is the width of the inner support structure  22  comprising an annular shape, and t is the height of the outer peripheral support structure  20 . Accordingly, in certain embodiments the base  12  is further characterized by the following mathematical relationships: 
         [0000]    
       
      
       w 
       o 
       =R−r  
      
     
         [0000]    
       
      
       w 
       i 
       =r 
       2 
       −r 
       1  
      
     
         [0000]        d= ½· t=r−r   2  
 
         [0000]    In embodiments, r 1  and r 2 , independent from one another, may be from about 0.0 to about 5.0 mm. For example, in embodiments in which the inner support structure comprises a circular shape with only a single radius, r 1  is zero and w i =r 2 , which may be from about 0.01 to about 5.0 mm. In embodiments in which the inner support structure comprises an annular ring, r 2 &gt;r 1  and r 1  and r 2 , independent from one another, may be from about 0.01 to about 5.0 mm. For example, r 1  may be 3.8 mm and r 2  may be 1.3 mm such that w i  is 2.5 mm. In embodiments in which there is no inner support structure, w i , r 1 , and r 2  are 0.0. 
         [0023]    The outer peripheral support structure  20  can still further be characterized by the feature angle (θ o ), the recess angle (θ 1 ), and the number of features (n), which have the following relationships: 
         [0000]      θ o =(360÷ n )−θ 1  0&lt;θ 1 &lt;θ o  
 
         [0024]    In embodiments, the height of the outer peripheral support structure (t) is from about 0.5 to about 2.0 mm, the height of the container (h) from the base to the stacking shoulder is about 39.4 mm, and the inner radius of the container at the stacking shoulder (R 1 ) is about 43.7 mm. In an embodiment, the approach angle is from about 2 degrees to about 10 degrees. Exemplary ranges of the foregoing variables are summarized in the table below. 
         [0000]    
       
         
               
               
               
             
               
               
               
               
             
           
               
                   
                   
               
               
                   
                 Dimension 
                 Exemplary Ranges 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 height of the container 
                 h 
                  20.0 mm-100.0 mm 
               
               
                   
                 inner radius of the 
                 R 1   
                 11.0 mm-55.0 mm 
               
               
                   
                 container at the stacking 
               
               
                   
                 shoulder 
               
               
                   
                 radius of the base 
                 R 
                 10.0 mm-50.0 mm 
               
               
                   
                 approach angle 
                 Φ 
                  2 degrees-10 degrees 
               
               
                   
                 inner radius of the outer 
                 r 
                  9.0 mm-49.0 mm 
               
               
                   
                 peripheral support 
               
               
                   
                 structure 
               
               
                   
                 outer radius of the inner 
                 r 2   
                  0.0 mm-40.0 mm 
               
               
                   
                 support structure 
               
               
                   
                 inner radius of the inner 
                 r 1   
                  0.0 mm-39.0 mm 
               
               
                   
                 support structure 
               
               
                   
                 height of the outer 
                 t 
                 0.5 mm-2.5 mm 
               
               
                   
                 peripheral support 
               
               
                   
                 structure 
               
               
                   
                 number of recesses 
                 n 
                  1-50 
               
               
                   
                   
               
             
          
         
       
     
         [0025]    In embodiments, a self-supporting filter element (not illustrated) known to those skilled in the art may be disposed in the container and either removably or permanently joined to an interior surface of the container. For example, the filter may be in the shape of an inverted hollow cone having a curved wall tapering evenly from a rim surrounding an opening. The filter element then may be placed in the container so that the apex of the cone is supported on and slightly flattened by the base of the container, thereby enlarging the volume within the cone and providing beneficial support for the filter element. 
         [0026]    In embodiments, the container provided herein further comprises a pierceable cover in a hermetically sealed relationship with the lip of the container, closing the opening to form a cartridge. The cover desirably is formed of an impermeable and imperforate material that may be pierced with an instrument, such as a tubular needle, through which hot water is delivered for preparation of the beverage. For example, in embodiments the cover may comprise a polymer film or a foil heat-sealed to the lip of the container. 
         [0027]    In embodiments, the containers may be prepared by molding and thermoforming the container from a thermoplastic material. Desirably, the thermoplastic material is substantially impermeable and imperforate. Non-limiting examples of suitable thermoplastic materials include polyolefins such as polypropylene and polyethylene, polystyrene, nylon, and other polymers. In particular embodiments, it is particularly desirable that the thermoplastic material be a bio-based resin, readily recycleable, and/or comprise at least a portion of recycled material. For example, in an embodiment the thermoplastic material may comprise a recycled polypropylene base resin. 
         [0028]    In embodiments, the thermoplastic material may be blended with one or more additives to impart the desired mechanical and thermal properties to the container. For example, in embodiments the thermoplastic material may be blended with one or more additives to impart the desired stiffness to the container. In an embodiment, the additive comprises an immiscible polymer that may function as a stress concentrator by hindering the natural ability of the thermoplastic material to deform plastically and promoting controlled crack propagation. Non-limiting examples of immiscible polymers that may be suitable for use with a thermoplastic material comprising polypropylene include acrylics, styrenics, or their blends and copolymers with polyolefins. In an embodiment, one additive comprises a nucleating agent. In an embodiment, a second additive comprises a metallic stearate, non-limiting examples of which include calcium stearate, magnesium stearate, zinc stearate, and combinations thereof. Other non-limiting examples of additives include calcium carbonate, talc, clays, and nano grades of these additives. 
         [0029]    Desirably, the containers provided herein have a puncture load of less than about 6 kg. As used herein, the “puncture load” means the force required to puncture the continuous puncture region in the base of the container using a needle. It should be appreciated that the puncture load depends in part on the type of needle used to measure the puncture load of a container. For example, the puncture load measured using a dull needle generally will be greater than the puncture load measured using a sharp needle. For example, in embodiments the containers may have a puncture load measured using a sharp needle of less than about 3 kg, less than about 2.75 kg, or less than about 2.5 kg. In embodiments, the containers may have a puncture load measured using a sharp needle of about 4.2 to about 3 kg, about 2.99 to about 2.75 kg, or about 2.74 to about 2.5 kg. In embodiments, the containers may have a puncture load measured using a dull needle of less than about 5 kg. For example, the containers may have a puncture load measured using a dull needle of about 4.0 to about 5.0 kg. 
         [0030]    In embodiments, the container may be configured to receive an insert in which the dry beverage ingredients are disposed. For example, the container may be configured to receive an insert comprising a filter cup in which are disposed the ingredients for preparing a beverage. For example, the container may further comprise a filter cup comprising a brew substance, non-limiting examples of which include coffee grinds, ground tea leaves, chocolate, flavored powders, and the like. The brew substance also may include a combination of dry milk, sugar or sugar substitute, or other flavorings to enhance the quality of the resulting beverage. 
         [0031]    The containers embodied herein are particularly suited for use in an automatic machine, such as a coffee brewing machine. Upon placing the container in the machine, a piercing member punctures the cover to introduce pressurized hot water through the hole where it comes into contact with the beverage ingredients disposed in the filter. A second piercing member punctures the base of the container at any position in the puncture region to enable the prepared beverage to flow out of the container and be dispensed into a cup or container for consumption by the consumer. 
         [0032]    The foregoing embodiments can be further understood and illustrated by the following non-limiting examples. 
       EXAMPLES 
     Example 1 
       [0033]    1.9 ounce containers were prepared from mono-layer sheets and compared to a commercially available K-Cup® to evaluate the effect of the different polymer formulations on the punctureability of an exemplary container. Polypropylene base resins included recycled PP, a homopolymer polypropylene (“Homopolymer PP 1”), and a medium impact polystyrene were used either alone or in combination with the additives white pigmented PS, CaCO 3  masterbatch 1 or CaCO 3  masterbatch 2, and PolyOne® proprietary masterbatch. The polymer formulations and results are provided in the following tables. 
         [0000]    
       
         
               
               
               
             
           
               
                   
               
               
                   
                   
                 Additives 
               
               
                 Cup 
                 Base Resin 
                 (w/w) 
               
               
                   
               
             
             
               
                 K-Cup ® 
                 Polystyrene 
                   
               
               
                 1 
                 Recycled PP 
                 N/A 
               
               
                 2 
                 Recycled PP 
                 White Pigmented PS 
               
               
                   
                   
                 (5%) 
               
               
                 3 
                 Recycled PP 
                 PolyOne ® ABPE 007 
               
               
                   
                   
                 (3%) 
               
               
                 4 
                 Homopolymer PP 1 
                 N/A 
               
               
                 5 
                 Homopolymer PP 1 
                 White pigmented PS 
               
               
                   
                   
                 (5%) 
               
               
                 6 
                 Homopolymer PP 1 
                 CaCO 3  masterbatch 1 
               
               
                   
                   
                 (3%) 
               
               
                 7 
                 Homopolymer PP 1 
                 CaCO 3  masterbatch 2 
               
               
                   
                   
                 (3%) 
               
               
                 8 
                 Medium impact 
                 N/A 
               
               
                   
                 Polystyrene 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                   
                   
                 Top 
                   
                   
                   
                   
                   
                   
                   
               
               
                   
                   
                 Top 
                 Load 
                   
                 Top 
                 Mid 
                 Bottom 
                   
                 Direct 
                 Puncture 
               
               
                   
                 Vacuum 
                 Load 
                 Flanges 
                 Flange 
                 Wall 
                 Wall 
                 Wall 
                 Heel 
                 Bottom 
                 Load 
               
               
                 Cup 
                 (in Hg) 
                 (lbs) 
                 (lbs) 
                 (10 −2 ) 
                 (10 −2 ) 
                 (10 −2 ) 
                 (10 −2 ) 
                 (10 −2 ) 
                 (10 −2 ) 
                 (lbs) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 K- 
                 4.58 
                 49.49 
                 4.40 
                 3.660 
                 1.325 
                 0.853 
                 1.665 
                 1.005 
                 2.225 
                 5.74 
               
               
                 Cup ® 
               
               
                 1 
                 7.52 
                 67.15 
                 9.356 
                 4.180 
                 1.165 
                 1.068 
                 1.395 
                 2.760 
                 4.390 
                 11.01 
               
               
                 2 
                 4.58 
                 49.49 
                 4.40 
                 3.660 
                 1.325 
                 0.853 
                 1.165 
                 1.005 
                 2.225 
                 10.91 
               
               
                 3 
                 6.05 
                 58.32 
                 6.88 
                 3.920 
                 1.470 
                 0.960 
                 1.280 
                 1.883 
                 3.308 
                 10.44 
               
               
                 4 
                 5.95 
                 47.16 
                 8.36 
                 3.915 
                 1.290 
                 2.347 
                 1.095 
                 1.785 
                 4.610 
                 N/A 
               
               
                 5 
                 6.71 
                 63.79 
                 8.64 
                 3.925 
                 1.355 
                 1.013 
                 1.300 
                 2.575 
                 4.745 
                 12.78 
               
               
                 6 
                 5.33 
                 37.33 
                 9.39 
                 4.060 
                 1.290 
                 0.984 
                 1.250 
                 2.045 
                 4.655 
                 N/A 
               
               
                 7 
                 5.03 
                 40.23 
                 10.22 
                 5.205 
                 1.375 
                 0.973 
                 1.085 
                 1.995 
                 4.485 
                 11.42 
               
               
                 8 
                 18.0 
                 196.80 
                 7.7 
                 3.500 
                 1.875 
                 1.672 
                 1.550 
                 1.010 
                 1.260 
                 4.34 
               
               
                   
               
             
          
         
       
     
         [0034]    The polystyrene-based K-Cup used as a control had the lowest “vacuum strength” of the containers tested, had a moderate top-load, the lowest side-load, and the lowest puncture load. Neither the neat polypropylene (Cup 4) nor the polypropylene with a 3% loading of CaCO 3  masterbatch 1 (Cup 6) were capable of being punctured. However, it was observed that the use of the recycled PP seemed to promote the punctureability of the container as did the additives CaCO 3  masterbatch 2 and White pigmented PS. 
       Example 2 
       [0035]    1.9 ounce containers were prepared from mono-layer sheets using various combinations of polypropylene and additives and compared to a commercially available K-Cup® to evaluate the effect of the polymer materials on the punctureability of an exemplary container. Polypropylene base resins included Homopolymer PP 1, High Stiffness Homopolymer PP 1, High Stiffness Homopolymer 2, High Stiffness Homopolymer PP 3, and Homopolymer PP 2, and were used either alone or in combination with the additives White Pigmented PS Nucleating Agent 1, Nucleating Agent 2, Stearate Masterbatch 1 or Stearate Masterbatch 2. The polymer formulations and results are provided in the following tables. 
         [0000]    
       
         
               
               
               
             
           
               
                   
               
               
                   
                   
                 Additives 
               
               
                 Cup 
                 Base Resin 
                 (w/w) 
               
               
                   
               
             
             
               
                 K-Cup ® 
                 Polystyrene 
                   
               
               
                 1 
                 Homopolymer PP 1 
                 White Pigmented PS 
               
               
                 2 
                 High stiffness Homopolymer PP 1 
                 (15%)  
               
               
                 3 
                 High stiffness Homopolymer PP 2 
               
               
                 4 
                 High stiffness Homopolymer PP 3 
               
               
                 5 
                 Homopolymer PP 2 
               
               
                 6 
                 Homopolymer PP 1 
                 Nucleating Agent 1 
               
               
                 7 
                 High stiffness Homopolymer PP 2 
                 (3%) 
               
               
                 8 
                 Homopolymer PP 1 
                 Nucleating Agent 2 
               
               
                   
                   
                 (3%) 
               
               
                 9 
                 Homopolymer PP 1 
                 Stearate Masterbatch 1 
               
               
                 10 
                 High stiffness Homopolymer PP 2 
                 (4%) 
               
               
                 11 
                 High stiffness Homopolymer PP 2 
                 Stearate Masterbatch 2 
               
               
                   
                   
                 (2%) 
               
               
                   
               
             
          
         
       
     
         [0000]    
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                   
               
               
                   
                 Puncture 
                 Top 
                   
                   
                   
               
               
                   
                 Load 
                 Load 
                 Top Load 
                 Punctured 
                 Opaque/ 
               
               
                 Cup 
                 (kg) 
                 (kg) 
                 Flanges (kg) 
                 (Yes/No) 
                 Translucent 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 K-Cup ® 
                 2.83 
                 21.4 
                 8.5 
                 Yes 
                 Translucent 
               
               
                 1 
                 2.4 
                 14.1 
                 6.26 
                 Yes 
                 Opaque 
               
               
                 2 
                 2.5 
                 15.3 
                 9.3 
                 Yes 
                 Opaque 
               
               
                 3 
                 3.00 
                 20.7 
                 8.7 
                 Yes 
                 Opaque 
               
               
                 4 
                 3.1 
                 20.1 
                 9.0 
                 Yes 
                 Opaque 
               
               
                 5 
                 2.6 
                 12.9 
                 6.5 
                 Yes (partly) 
                 Opaque 
               
               
                 6 
                 2.7 
                 9.61 
                 7.1 
                 Yes 
                 Translucent 
               
               
                 7 
                 2.73 
                 20.1 
                 8.1 
                 Yes 
                 Translucent 
               
               
                 8 
                 4.2 
                 10.57 
                 7.3 
                 Yes 
                 Translucent 
               
               
                 9 
                 4.19 
                 16.05 
                 8.3 
                 Yes 
                 Translucent 
               
               
                 10 
                 2.91 
                 17.7 
                 8.8 
                 Yes 
                 Translucent 
               
               
                 11 
                 2.70 
                 22.4 
                 9.3 
                 Yes 
                 Translucent 
               
               
                   
               
             
          
         
       
     
         [0036]    It should be apparent that the foregoing relates only to certain embodiments of the present application and the resultant patent. Numerous changes and modifications may be made herein by one of ordinary skill in the art without departing from the general spirit and scope of the invention as defined by the following claims and the equivalents thereof.