Abstract:
A container for holding ground coffee or tealeaves. The container may include a body and a lip extending from the body. The lip may include a top substantially flat surface and a width of no more than about 2.6 millimeters (about 0.1 inch).

Description:
BACKGROUND OF INVENTION  
       [0001]     1. Technical Field  
         [0002]     The present invention relates generally to a container for brewing material and more particularly relates to a pod for use in the automatic brewing of coffee, tea, and other beverages.  
         [0003]     2. Background of the Invention  
         [0004]     Various types of automatic coffee and tea dispensers are known. Generally described, these dispensers hold a measure of ground coffee, tealeaves, or other type of brewable material in a container of some sort. Hot water generally is added to the material so as to brew the beverage. The material is generally held in some sort of disposable container that must be opened or penetrated so as to allow the hot water to pass therethrough.  
         [0005]     One drawback with these known brewing devices, however, is that the elements of the device that come into contact with the brewing material generally must be cleaned. Further, the container for the material must be inserted and aligned in the dispenser for each beverage. As a result, the beverage dispenser as a whole may be somewhat slow between beverage cycles as the container is inserted, aligned, removed and/or the dispenser elements are cleaned.  
         [0006]     There is a desire therefore, for a device that brews a beverage with a quick cycle time. The device preferably should be relatively inexpensive and easy to use and produce a high quality beverage. Likewise, the device preferably should be adaptable for different types of brewing materials and amounts.  
       SUMMARY OF INVENTION  
       [0007]     The present invention thus may provide for a container for holding ground coffee or tealeaves. The container may include a body and a lip extending from the body. The lip may include a top substantially flat surface and a width of no more than about 2.6 millimeters (about 0.1 inch).  
         [0008]     The body may include a sidewall and a base. The base may include a number of apertures therein, a number of support ribs thereon, and a number of spikes thereon. Each of the spikes may include a base surrounded by a number of blades.  
         [0009]     The lip may include a flange extending from the flat surface. The flange may extend downwardly at an angle so as to form a pocket with the body. The pocket may include an upper curved radius.  
         [0010]     The container also may include a lid positioned within the body. The lid may include a concave shape and a number of apertures therein. The body may include one or more over-cuts therein for the lid.  
         [0011]     The container also may include one or more layers of filter paper positioned within the body. A foil envelope for holding the ground coffee or the tealeaves also may be used. The container may be made of polystyrene, polyethylene, or polypropylene.  
         [0012]     A further embodiment of the present invention may provide for a container for holding ground coffee or tealeaves. The container may include a base with a number of apertures therein, a circular sidewall extending from the base, and a lip extending from the sidewall. The lip may include a top substantially flat surface and a flange extending downwardly from the flat surface. The flange may include a width of no more than about 2.6 millimeters (about 0.1 inch). The base may include a number of spikes thereon.  
         [0013]     A further embodiment of the present invention may provide for a dispenser for brewing a beverage from a beverage material. The dispenser may include a pod with the beverage material therein, a pod holder, and an injection head. The pod may include a lip extending from a body. The pod holder may be adapted to receive the pod therein and support the lip of the pod. The injection head may include about 136 to 160 kilograms (about 300 to 350 pounds) of force applied to the lip of the pod. The dispenser further may include a number of pods.  
         [0014]     The pod may include about five (5) to about eight (8) grams of a plastic material. The dispenser further may include a turret assembly such that the turret assembly may include the pod holder and an injector assembly such that the injector assembly may include the injection head. The injector assembly may include a drive mechanism so as to maneuver the injection head. The drive mechanism may maneuver the injection head about 6.4 to about 12.7 millimeters (about one-quarter to about one-half inches) in a substantially vertical direction. The lip may include a substantially flat top surface and the injection head may include a sealing ring sized to accommodate the flat top surface. The injection head provides water pressurized at about 1.4 to 14 kilograms per square centimeter (about 20 to about 200 pounds per square inch) to the pod. The body may include a number of spikes therein.  
         [0015]     A method of the present invention may provide for preparing a beverage from a beverage material. The method may include placing the beverage material within a container, tamping the beverage material down with a lid of the container, positioning the lid into the container, and injecting the container with water pressurized water at about 1.4 to 14 kilograms per square centimeter (about 20 to about 200 pounds per square inch).  
         [0016]     These and other features of the present invention will become apparent upon review of the following detailed description of the preferred embodiments when taken in conjunction with the drawings and the appended claims. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0017]      FIG. 1  is a perspective view of one embodiment of a beverage dispenser system for use with the present invention.  
         [0018]      FIG. 2  is a top plan view of the beverage dispenser system of  FIG. 1 .  
         [0019]      FIG. 3  is a perspective view of a turret system of the beverage dispenser system of  FIG. 1 .  
         [0020]      FIG. 4  is a perspective view of an injector assembly of the beverage dispenser system of  FIG. 1 , with the guide wheels and the return spring of the support plate shown in phantom lines.  
         [0021]      FIG. 5  is a rear perspective view of the injector assembly of the beverage dispenser system of  FIG. 1 , with the idler wheel and the limit switch shown in a cut away view.  
         [0022]      FIG. 6  is a side cross-sectional view of a configuration of brewing material for use with the present invention.  
         [0023]      FIG. 7  is a side cross-sectional view of an alternative configuration of brewing material for use with the present invention.  
         [0024]      FIG. 8  is a top perspective view of a pod of the present invention.  
         [0025]      FIG. 9  is a bottom perspective view of the pod of  FIG. 8 .  
         [0026]      FIG. 10  is a side plan view of the pod of  FIG. 8 .  
         [0027]      FIG. 11  is a bottom plan view of the pod of  FIG. 8 .  
         [0028]      FIG. 12  is a side cross-sectional view of the pod of  FIG. 8 .  
         [0029]      FIG. 13  is a side cross-sectional view of the lip of the pod of  FIG. 8 .  
         [0030]      FIG. 14  is a side cross-sectional view of an alternative embodiment of a pod of the present invention with a lid thereon[115] FIG. 15  is a side cross-sectional view of the interior wall of the pod of  FIG. 14 [116] FIG. 16  is a perspective view of an alternative embodiment of a pod of the present invention.  
         [0031]      FIG. 17  is a top plan view of the pod of  FIG. 16 .  
         [0032]      FIG. 18  is a side cross-sectional view of the pod of  FIG. 16 .  
         [0033]      FIG. 19  is a perspective view of a spike used in the pod of  FIG. 16 . 
     
    
     DETAILED DESCRIPTION  
       [0034]     Commonly owned U.S. patent application Ser. No. 10/071,643, entitled “COFFEE AND TEA DISPENSER”, is incorporated herein by reference.  
         [0035]     Referring now to the drawings, in which like numerals refer to like elements throughout the several views,  FIGS. 1 and 2  show one application of a beverage dispenser system  100 . In these figures, a pod brewing apparatus  300  is shown. The pod brewing apparatus  300  may include a heat exchanger  150  positioned within a hot water reservoir  160  and in communication with aninjection nozzle  200  as is shown. In this embodiment, the elements of the beverage dispenser system  100  as a whole are mounted onto a dispenser frame  305 . The dispenser frame  305  may be made out of stainless steel, aluminum, other types of metals, or other types of substantially noncorrosive materials.  
         [0036]     The injection nozzle  200  may interact with one or more pod cartridges  210  so as to produce the desired beverage in a cup  230  or any other type of receptacle. The pod cartridges  210  may be positioned in the beverage dispenser system  100  within a turret assembly  310 . The turret assembly  310  may be fixedly attached to the dispenser frame  305 . As is shown in  FIG. 3 , the turret assembly  310  may include a turret plate  320  positioned within a turret frame  325 . The turret frame  325  may be made out of stainless steel, aluminum, other types of conventional metals, or similar types of substantially noncorrosive materials. The turret plate  320  may be substantially circular. The turret plate  320  may include a number of pod apertures  330 . The pod apertures  330  may be sized to accommodate the pod cartridges  210 . The turret plate  320  may spin about a turret pin  340 . A turret motor  350  may drive the turret assembly  310 . The turret motor  350  may be a conventional AC motor or a similar type of device. The turret motor  350  may drive the turret assembly  310  at about six (6) to about thirty (30) rpm, with about twenty-five (25) rpm preferred.  
         [0037]     The turret plate  320  also may have a number of detents  360  positioned about its periphery. The detents  360  may be positioned about each of the turret apertures  330 . The detents  360  may cooperate with one or more limit switches  365  so as to control the rotation of the turret plate  320 . The rotation of the plate  320  may be stopped when the limit switch  360  encounters one of the detents  360 .  
         [0038]     Positioned adjacent to the turret assembly  310  may be an injector assembly  400 . The injector assembly  310  may be fixedly attached to the dispenser frame  305 . The injector assembly  400  also may include an injector frame  410  extending above the turret assembly  310 . The injector frame  410  may be made out of stainless steel, other types of metals, or similar types of substantially noncorrosive materials.  
         [0039]     As is shown in  FIGS. 4 and 5 , the injector assembly  400  may include the injection nozzle  200  as described above. The injection nozzle  200  may have a narrow tip so as to penetrate the pod cartridge  210  if needed or a wide mouth to accommodate the entire pod cartridge  210 . The injector assembly  400  may include an injector head  420  that cooperates with the injection nozzle  200 . The injector head  420  may be slightly larger in diameter than the pod cartridges  210 . The injector head  420  also may be made out of stainless steel, plastics, or similar types of substantially non-corrosive materials. The injector head  420  may include a sealing ring  430  positioned about its lower periphery. The sealing ring  430  may be made out of rubber, silicone, or other types of elastic materials such that a substantially water tight seal may be formed between the injector head  420  and the pod cartridge  210 . The heat exchanger  150  may be in communication with the injector head  420  so as to provide hot, pressurized water to the pod cartridges  210 .  
         [0040]     The injector head  420  may be moveable in a substantially vertical plane via a cam system  440 . (The terms “vertical”and “horizontal”are used as a frame of reference as opposed to absolute positions. The injector head  420  and the other elements described herein may operate in any orientation.) A cam system drive motor  450  may drive the cam system  440 . The drive motor  450  may be a conventional AC motor similar to the turret motor  350  described above. The drive motor  450  also may be a shaded pole or a DC type motor. The drive motor  450  may rotate an eccentric cam  460  via a drive belt system  470 . The drive motor  450  and the gear system  470  may rotate the eccentric cam  460  at about six (6) to about thirty (30) rpm, with about twenty-five (25) rpm preferred. The eccentric cam  460  may be shaped such that its lower position may have a radius of about 4.1 to about 4.8 centimeters (about 1.6 to 1.9 inches) while its upper position may have a radius of about 3.5 to 4.1 centimeters (about 1.3 to about 1.7 inches).  
         [0041]     The eccentric cam  460  may cooperate with an idler wheel  480 . The idler wheel  480  may be in communication with and mounted within a support plate  490 . The support plate  490  may maneuver about the injector frame  410 . The support plate  490  may be made out of stainless steel, other types of steel, plastics, or other materials. The support plate  490  may be fixedly attached to the injector head  420 . The support plate  490  may have a number of guide wheels  500  positioned thereon such that the support plate  490  can move in the vertical direction within the injector frame  410 . A return spring  520  also may be attached to the support plate and the injector frame  410 . A limit switch  530  may be positioned about the cam  460  such that its rotation may not exceed a certain amount.  
         [0042]     The injector head  420  thus may maneuver up and down in the vertical direction via the cam system  440 . Specifically, the drive motor  450  may rotate the eccentric cam  460  via the gear system  470 . As the eccentric cam  460  rotates with an ever-increasing radius, the idler wheel  480  pushes the support plate  490  downward such that the injector head  420  comes in contact with a pod cartridge  210 . The eccentric cam  460  may lower the injector head  420  by about 6.4 to about 12.7 millimeters (about one-quarter to about one-half inches). Once the injector head  420  comes into contact with the pod cartridge  210 , the eccentric cam  460  may continue to rotate and increases the pressure on the pod cartridge  210  until the cam  460  reaches the limit switch  530 . The injector head  420  may engage the pod cartridge  210  with a downward force of about 136 to 160 kilograms (about 300 to 350 pounds). The sealing ring  430  thus may form a substantially airtight and water tight seal about the pod cartridge  210 . The drive motor  450  may hold the cam  460  in place for a predetermined amount of time. The cam system  440  may then be reversed such that the injector head  420  returns to its original position.  
         [0043]     Once the injection nozzle  200  of the injector head  420  is in contact with the pod cartridge  210 , the hot, high pressure water may flow from the heat exchanger  150  into the injector head  420 . The water may be at about 82 to about 93 degrees Celsius (about 180 to about 200 degrees Fahrenheit). The incoming water flow may be pressurized at about 11 to about 14 kilograms per square centimeter (about 160 to 200 pounds per square inch). The pressure of the water passing through the pod cartridge  210  may be about 1.4 to about 14 kilograms per square centimeter (about 20 to about 200 pounds per square inch). The pressure of the water flowing through the pod cartridge  210  may vary with the nature of the beverage.  
         [0044]     As is shown in  FIGS. 6 and 7 , the pod cartridges  210  may be filled with different types of grinds, leaves, or other types of a brewing material  550 . In the case of a single serving sized espresso beverage of about thirty (30) milliliters, about six (6) to about eight (8) grams of espresso grinds may be placed in the pod cartridge  210 . Likewise, about six (6) to about (8) grams of coffee grinds may be added to the pod cartridge  210  to produce about a 240 milliliter (about eight (8) ounce) cup of coffee. About three (3) to about five (5) grams of tealeaves may be added to the pod cartridge  210  in order to make about a 150 milliliter (about five (5) ounce) cup of tea.  
         [0045]     The brewing material  550  may be positioned within one or more layers of filter paper  560 . The filter paper  560  may be standard filter paper used to collect the brewing material  550  while allowing the beverage to pass therethrough. The pod cartridge may have an upper filter layer  570  and a lower filter layer  580 . The brewing material  550  itself may be positioned directly between the upper and lower filter layers  570 ,  580 . Alternatively, the brewing material  550  may be placed within a foil envelope  590 . The foil envelope  590  may serve to keep the brewing material  550  therein fresh and out of contact with the ambient air. Alternatively, the entire pod cartridge  210  may be placed within a foil envelope, either individually or as a group, until the pod  210  is ready for use.  
         [0046]      FIGS. 8-12  show an embodiment of the pod cartridge  210  that may be used with the beverage dispenser system  100  or in other types of beverage systems. The pod cartridge  210  may be substantially in the shape of a cup  600 . The cup  600  may be made out of a conventional thermoplastic such as polystyrene, polyethylene, or polypropylene. Alternatively, stainless steel or other types of substantially non-corrosive materials also may be used. The cup  600  may be substantially rigid.  
         [0047]     The cup  600  may include a substantially circular sidewall  610  and a substantially flat base  620 . The sidewall  610  and the base  620  of the cup  600  may be molded and form a unitary element or a separate sidewall  610  and a separate base  620  may be fixedly attached to each other. The sidewall  610  and the base  620 , as well as the cup  600  as a whole, may have any convenient diameter so as to accommodate the pod apertures  330  of the turret plate  320  of the turret assembly  310  and the injector head  420  of the injector assembly  400 . Alternatively, the sidewall  610  and the base  620  of the cup  600  may have any convenient diameter so as to accommodate other any type of beverage dispenser system  100 .  
         [0048]     The sidewall  610  of the cup  600  may have any convenient depth so as to accommodate an appropriate amount of the brewing material  550 . In this embodiment, the sidewall  610  may have an inside diameter of about 3.9 centimeters (about 1.535 inches), an outside diameter of about 4.03 centimeters (about 1.586 inches) and a wall thickness of about 1.295 millimeters (about 0.051 inches). The sidewall  610  also may have a depth of about 2.43 centimeters (about 0.955 inches) with the base  620  having an additional depth of about 0.318 centimeter (about 0.125 inches). Such a configuration of the sidewall  610  and the base  620  of the cup  600  may hold about six (6) to about sixteen (16) grams of the brewing material  550 , depending upon the size of the desired beverage, i.e., eight (8), twelve (12), or sixteen (16) ounces. These dimensions are for purposes of example only. The sidewall  610  and the base  620  of the cup  600  may take any desired or convenient size or shape. For example, the sidewall  610  may be straight, tapered, stepped, or curved if desired.  
         [0049]     The base  620  also may include a bottom floor  630 . The bottom floor  630  may include a number of apertures  640  formed therein. The apertures  640  may extend through the width of the floor  630 . In this embodiment, the apertures  640  may be largely circular in shape with a diameter of about 1.6 millimeters (about 0.063 inches). Any desired shape or size, however, may be used. In this embodiment, about 54 apertures  640  are used herein, although any number may be used. The base  620  also may include a number of support ribs  650  supporting the floor  630 . An inner circular rib  660 , an outer circular rib  670 , and a number of radial ribs  680  may be used. Any design or number of ribs  660  may be used. In this embodiment, the ribs  650  may have a depth of about 2.54 millimeters (about 0.1 inch) and the floor  630  may have a depth of about 1.78 millimeters (about 0.07 inches), although any desired thickness may be used.  
         [0050]     The sidewall  610  of the cup  600  also may include an upper lip  700 . The upper lip  700  may include a substantially flat top portion  710  and a downwardly angled flange  720  extending from the top portion  710 . The flange  720  may extend downwardly so as to form a pocket  730  with the sidewall  610 . The top of the pocket  730  may form a curved inner radius  735 . As is shown in  FIG. 13 , the sidewall  610  may or may not include an outer step  740  within the pocket  730 .  
         [0051]     In this embodiment and by way of example only, the flat top portion  710  of the upper lip  700  may have width of about 2.54 millimeters (about 0.01 inch) extending in the horizontal direction. The flange  720  may have the length of about 2.2 millimeters (about 0.087 inch). The flange  720  and the pocket  730  of the lip  700  are sized to accommodate the size of the pod apertures  330 . Specifically, the lip  700  is configured to accommodate the size of the pod apertures  330  and the expected force of the injector head  420  while using as little material as possible.  
         [0052]      FIGS. 14 and 15  show a further embodiment of the cup  600 . In this embodiment, the sidewall  610  of the cup  600  may include a number of over-cuts  760  formed therein. In this embodiment, a first over-cut  770  and a second over-cut  780  may be used. Any number of over-cuts  760 , however, may be used. The over-cuts  760  may be continuous around the inner circumference of the side wall  610  or the over-cuts  760  may be intermittent. The over-cut  760  may cooperate with a lid  790 . The lid  790  may have edges  800  that are substantially wedge shaped to fit and remain within the over-cut  760 . The use of the wedge shaped edge  800  ensures that the lid  790  remains in place. The edges  800  may be continuous or intermittent so as to mate with the over-cut  760 . The lid  790  preferably is bowed inward or largely concave in shape.  
         [0053]     The lid  790  may be placed in the first or second over cut  770 ,  780  depending upon the amount of brewing material  550  that is desired to be placed within the cup  600 . The lid  790  is bowed downward so as to tamp the brewing material  550  down under pressure and to keep the brewing material  550  therein from shifting. The lid  790  may compact the brewing material  550  with at least about nine (9) kilograms of compressive force (about twenty (20) pounds of force). The lid  790  also may have a number of apertures  810  therein so as to permit water from the injector head  420  to pass therethrough. Depending on the nature of the injector head  420 , the use of the lid  790  may not be necessary. Instead, a foil wrapper or any other covering may be used. Likewise, the over-cuts  760  also may be eliminated or modified as desired.  
         [0054]      FIGS. 16-19  show a further embodiment of the present invention, a spiked pod  850 . The spiked pod  850  may use the cup  600 , the side wall  610 , the base  620 , the lip  700 , and the elements thereof as described above with the pod cartridge  210 . The spiked pod  850  also may include a number of spikes  860  positioned along the floor  630  of the base  620 . The spikes  860  may serve to puncture a package for the brewing material  550  as will be described in more detail below. In this embodiment, about eighteen (18) spikes  860  may be used. Any desired number of spikes, however,  860  may be used. The spikes  860  may be aligned along the radial ribs  680  of the base  620  or elsewhere along the floor  630 .  
         [0055]     As is shown in, for example,  FIG. 19 , the spikes  860  may include three (3) triangular blades  870  surrounding a base  880 . The tips of the blades  870  may form a puncture area  890 . The blades  860  may have any desired shape. The blades  870  may have a height of about 6.35 millimeters (about 0.25 inch) and the base  880  may have a height of about 3.8 millimeters (about 0.15 inches) such that the puncture area  890  may be about 2.54 millimeters (about 0.1 inches) in length above the base  880 . Any desired size, however, may be used.  
         [0056]     In use, the lower layer  580  of filter paper may be placed with the cup  600  of the pod cartridge  210 . The lower layer  580  may be positioned along the floor  630  of the base  620 . An amount of the brewing material  550  then may be positioned therein. The upper layer  570  of the filter paper then may be placed on the brewing material  550  if desired. The lid  790  then may be placed within the cup  600  so as to tap down the brewing material  550 . Once the lid  790  has compacted the brewing material  550 , the edge  800  of the lid  790  is positioned within the appropriate over-cut  760  within the side wall  610  of the cup  600 . The pod  210  then may be sealed or otherwise shipped for use with the beverage dispenser system  100  or otherwise.  
         [0057]     The pod  210  may be positioned within one of the pod apertures  330  in the turret assembly  310 . Specifically, the outer edge of the pod aperture  330  aligns with the flange  720  of the lip  700  of the cup  600 . A pod or other device with a convention square lip would extend too far out of the pod aperture  330  to function with the injection head  420  of the injector assembly  310 . The injector head  420  then may be positioned about the pod  210 . The sealing ring  630  of the injector head  420  may seal about the top portion  710  of the lip  700  of the cup  600 . The use of a rounded lip or a lip with a non-flat shape may cause damage to the sealing ring  430  given the amount of pressure involved, i.e., as described above, the injector head  420  may engage the pod cartridge  210  with a downward force of about 136 to about 160 kilograms of force (about 300 to about 350 pounds) and the incoming water flow may be pressurized at about eleven (11) to about fourteen (14) kilograms per square centimeter (about 160 to 200 pounds per square inch (psi)). The pressure of the water flowing through pod cartridge  210  may vary with the nature of the brewing material  550  from about 1.4 to about 14 kilograms per square centimeter (about twenty (20) to about 200 pounds per square inch).  
         [0058]     The water passing through the injection head  420  may spread out over the lid  790  and the apertures  810  thereof and into the brewing material  550 . The brewed beverage may then pass through the apertures  640  in the base  620  of the cup  600 .  
         [0059]     The lip  700  as well as the base  620  of the cup  600  are designed to use as little material as possible while being able to withstand the water pressures described above with out deformation. The cup  600  as a whole may have about five (5) to about eight (8) grams of plastic material therein when using, for example, polypropylene homopolymer. The configuration of the lip  700  may save about 0.4 to about 0.6 grams or about ten percent (10%) of the plastic required.  
         [0060]     In the embodiment of the spiked pod  850 , the brewing material  550  may be positioned within the foil envelope  590 . At least the lower filter layer  580  also may be placed within the cup  600 . The injection nozzle  200  may penetrate the foil envelope  590  or water may otherwise flow into the cup  600  with the water pressure described above. This water pressure may force both the lower filer layer  580  and the foil envelope  590  against the spikes  860  of the spiked pod  850 . This pressure may allow these spikes  860  to penetrate both the lower filter area  580  and the foil envelop  590 . The punctures caused by the spikes  860  may allow the brewed beverage to pass therethrough while substantially maintaining the remaining brewing material  550  therein. The spikes  860  may provide substantially uniform penetration of the foil envelope  590 . The brewing material  590  also may be contained within other types of structures that may be penetrated by the spikes  860 .  
         [0061]     It should be apparent that the foregoing relates only to the preferred embodiments of the present invention and that numerous changes and modifications may be made herein without departing from the spirit and scope of the invention as defined by the following claims and the equivalents thereof.