Abstract:
A cartridge for preparing a beverage comprises a container, a pod for containing a substance from which a beverage is to be extracted, a separating element for protecting the pod, and one or more supporting elements for holding the separating element in a preferred position. The cartridge is of the type which is pierced by at least one piercing tool to allow the injection of a liquid and extraction of a beverage. The separating element comprises a platform upon which the pod is disposed. The platform forms a boundary within the container, thereby defining first and second portions of the container. Liquid is injected into the first portion of the container, and the beverage is removed from the second portion. The separating element is positioned an appropriate distance from the piercing tools by the supporting elements.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Patent Application Ser. No. 61/679,148, filed on Aug. 3, 2012, the entire contents of which are incorporated herein by reference. 
    
    
     DESCRIPTION OF THE FIELD 
     The invention relates to cartridges for preparing beverages and methods of manufacturing such cartridges. 
     BACKGROUND OF THE INVENTION 
     It is known to prepare beverages by the use of cartridges by piercing the cartridge at entrance and exit points to allow passage of a liquid through a substance contained within the cartridge. While passing through the substance under pressure, the liquid extracts the desired aromas and flavours. 
     The substance is often held within a filter or pod which is secured within the cartridge. The pod is water-permeable, and may be made of a material which can be torn by the piercing elements that create the entrance and exit points. There is also a risk of damage to the pod due to high pressures within the cartridge. 
     There are proposals that separate the pod from the portions of the container that are pierced. However, some such proposals can require high manufacturing costs. 
     It is an object of the invention to obviate or mitigate one or more of the disadvantages described above. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the invention, a cartridge for the preparation of beverages is provided, wherein the cartridge comprises a container for defining an interior space, a separating element for defining two portions of the interior space, one or more supporting elements for positioning the separating element in a desired location, and a pod for containing the substance from which the beverage is to be extracted. The separating element is constructed to allow fluid communication between the first and second portions of the interior space. The pod is disposed on the separating element. 
     The separating element is formed separately from the container and disposed within the container as an unaffixed piece. Similarly, the pod is supported only by the separating element. It is believed that this may reduce manufacturing costs, since the pod and separating element will remain in place without any fasteners or adhesives. Thus, steps of affixing the pod and the separating element to the container are not required. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings. 
         FIG. 1  is a front view of the cartridge and its components. 
         FIG. 2  is a front view of the container. 
         FIG. 3  is a front view of a different embodiment of the cartridge. 
         FIG. 4  is a front view of one embodiment of the separating element. 
         FIG. 5  is a top view of one embodiment of the separating element. 
         FIG. 6  is a top view of another embodiment of the separating element. 
         FIG. 7  is an exploded view of the cartridge and its components. 
         FIG. 8  is a front/top perspective view of another embodiment of the separating element. 
         FIG. 9  is an exploded view of another embodiment of the cartridge and its components. 
         FIG. 10  is a front/top perspective view of another embodiment of the separating element. 
         FIG. 11  is a front view of another embodiment of the container. 
         FIG. 12  is an exploded view of another embodiment of the cartridge and its components. 
         FIG. 13  is a front view of another embodiment of a cartridge. 
     
    
    
     DETAILED DESCRIPTION 
     For the purpose of the discussion of the present invention, the word “form” and any of its derivatives, including but not limited to the words “formed” and “forming”, are defined to mean any method or any step of a method of creating an article. For example, “form” includes, but is not limited to, injection moulding, deep drawing, punching, compression forming, vacuum forming, heat sealing, and ultrasonic welding. The method may furthermore comprise multiple steps, such as in the case that a first component of an article is manufactured, and a second manufactured component is then affixed to the first component. 
     Additionally, the phrase “formed around” may include any method of manufacturing which results in an article comprising a first component contained within a second component. That is, “formed around” includes, but is not limited to, the following processes: the process of forming a first element, forming a first component of a second element, disposing the first element within the first component of the second element, forming a second component of the second element, and affixing the second component to the first component; the process of suspending a first element within a medium, moulding a second element around the medium, and removing the medium from within the second element; and the process of forming a fully enclosed first element, opening the first element, placing a second element into one portion of the first element, and closing the first element. 
     Referring to  FIGS. 1 and 2 , there is shown a cartridge  100  for preparing a beverage. The cartridge comprises a container  110 , a separating element  120 , one or more supporting elements  130 , and a pod  140  containing a powder, grounds, or other substance from which the beverage may be extracted, such as ground coffee beans or tea leaves, for example. The pod  140  can include a filter, sachet, or other bag that is permeable to fluids while retaining the substance (from which the beverage may be extracted) within it. 
     The container  110  comprises one or more side walls  111  extending between a lid  113  at a first end and a bottom surface  112  at a second opposing end, defining an interior space  114 . The separating element  120  separates the interior space  114  into a first portion  115  and a second portion  116  while permitting fluid communication between the first portion  115  and second portion  116 . The pod  140  is disposed on the separating element  120 , and thereby maintains its position in the first portion  115  of the interior space  114 . There may be no requirement of a fastening means to fasten the pod  140  to the separating element  120  or the container  110 , particularly as it may rest upon the separating element  120  when the cartridge  100  is in use. Optionally, a beverage additive may be disposed loosely, or in a second pod, between the separating element  120  and the bottom surface  112  within the second portion  116 . The beverage additive, may, for example, be a powdered cream or milk, or cream or milk replacement, non-dairy cream, foam cream, sugar, chocolate, essence, mint powder, or other foods or substances. The beverage additive may be added to enhance the flavour, nutrients, appearance and/or aroma of the resulting beverage. 
     In use, the cartridge  100  is placed in a machine which injects a liquid into the first portion  115  of the interior space  114  by means of an inlet. The inlet can be formed by a piercing element of the machine which can also inject the liquid. While passing, under pressure, through the pod  140 , the liquid extracts the desired aromas and flavours from the substance. The resulting flavoured beverage is communicated by the separating element  120  and into the second portion  116  of the interior space  114  by the pressure, gravity and/or other motive force. If a beverage additive has been disposed between the separating element  120  and the bottom surface  112 , the flavoured beverage mixes with the beverage additive. The flavoured beverage then exits the cartridge  100  by an outlet, which can also be formed by a piercing element. The flavoured beverage may then pass into a beverage receptacle for consumption. 
     For injecting the liquid, in one embodiment, the lid  113  is piercable to form an inlet, which may be created by a first piercing tool  200 , to accommodate the inflow of a liquid, such as water. In another embodiment, as shown in  FIG. 3 , one or more side walls  111  along the first portion  115  may be pierced using a first side piercing tool  202  to form the inlet. 
     For extracting the liquid, in one embodiment, the bottom surface  112  is piercable to form an outlet, which may be created by a second piercing tool  300 , to accommodate the outflow of the beverage. In another embodiment, as shown in  FIG. 3 , one or more side walls  111  along the second portion  116  may be pierced using a second side piercing tool  302  to form the outlet. 
       FIGS. 4, 5, and 6  show embodiments of the separating element  120 . The separating element  120  comprises a first surface  121  sufficient to support the pod in the first portion  115  of the interior space  114 . Generally, the separating element  120  extends toward the side walls  111 , though not necessarily a snug fit along the side walls  111 , as will be explained below. 
     The first surface  121  of the separating element  120  is generally shaped as a substantially planar surface to support the pod, while a second surface  122  on the opposing face of the separating element facing the second portion  115  of the interior space  114  need not have any specific shape as it does not need to support the pod. 
     The separating element  120  permits fluid communication from the first portion  115  to the second portion  116  of the interior space  114 . In one embodiment, drainage passages  123  extend from the first surface  121  to the second surface  122 , permitting fluid communication from the first portion  115  to the second portion  116  of the interior space  114 . In another embodiment, fluid communication is achieved by forming the separating element  120  from a water permeable material. In yet another embodiment, fluid communication is achieved by forming the separating element  120  such that it is not a snug fit along all of the side walls  111  (such that its widest dimension is smaller than the adjacent dimension of the side walls of the container), thereby permitting fluid to pass between an edge of the separating element  120  and the one or more side walls  111 . 
     The separating element elevates the pod so as to prevent damage to the pod due to contact with the piercing tool  300 . Additionally, the first surface  121  of the separating element  120  supports the pod  140  which may assist to prevent tearing under the pressure of the injected liquid. 
     In one embodiment shown in  FIG. 6 , the separating element  120  comprises a plurality of concentric rings, joined by one or more spokes which extend radially from the centre of the rings toward the outermost ring, with the drainage passages  123  being the gaps between said rings. In a preferred embodiment, the separating element comprises two concentric rings joined by one or more spokes, the rings being separated by a distance greater than the width of a widest ring. It should be understood that individual spokes need not extend from the centre of the rings toward the outermost rings, but could instead by replaced by a set of discontinuous spokes joining the rings together in any way. It should also be understood that either the spokes or rings could be omitted to provide a non-unitary separating element, though such an embodiment may be more complex and costly. 
     Referring back to  FIG. 4 , the supporting elements  130  may be independent of the separating element  120  and/or cartridge  100 , or they may be integral components of another element of the cartridge  100 . For example, the supporting elements  130  may be formed with the separating element  120  or with the one or more side walls  111  of the container  110 . 
     In a preferred embodiment, the supporting elements  130  are a set of at least three members integral with the separating element  120 , extending from the second surface  122  of the separating element  120  toward the bottom wall  112 . The integrated separating element  120  and supporting elements  130  are placed within the container, as shown in  FIG. 7 , resulting in the free ends of the supporting elements being aligned to abut the bottom surface  112  of the container  110 , as shown in  FIG. 1 . The length of the supporting elements  130  determines the elevation of the separating element, and thereby also the distance that the pod is separated from the piercing tool  300 . The supporting elements are of a length that they provide sufficient distance between piercing tool  300  and the separating element without moving the pod into near proximity with the first piercing tool  200 . 
     In another embodiment, as shown in  FIGS. 8 and 9 , a second separating element  220  is connected to the ends of the supporting elements  130  opposite the separating element  120 . The second separating element  220  permits fluid communication from the second portion  116  to a beverage receptacle via an outlet formed by a piercing element. In the example of  FIG. 8 , the second separating element  220  has the same shape, structure, and drainage passage pattern as the separating element  120 , which in this example, comprises a plurality of concentric rings and radial spokes, and drainage passages  123 . It will be appreciated that the second separating element  220  may comprise of a different shape, structure, and/or drainage passage pattern than the separating element  120 . 
     The second separating element  220  can facilitate the placement of a combined structure of the separating element  120 , supporting elements  130  and second separating element  220  within the container  110 , without having to specifically align the free ends of the supporting elements  130  to abut the bottom surface  112  of the container  110  such that the supporting element  120  is spaced apart from the bottom surface  112  of the container  110  (as shown in  FIG. 7 ). In the example of  FIG. 9 , either separating element  120  or  220  can be aligned to abut the bottom surface  112  of the container  110 , resulting in the other separating element to be spaced apart from the bottom surface  112  to support the pod  140 . It will be appreciated that the second separating element  220  can perform the function of the separating element  120  to support the pod  140 , when the separating element  120  is aligned to abut the bottom surface  112  of the container, resulting in the second separating element  220  to be spaced apart from the bottom surface  112  by supporting elements  130 . 
     In an embodiment, the second piercing tool  300  can be aligned with the drainage passages  123  of the separating element abutting the bottom surface  112 , so as to not pierce through the separating element. In another embodiment, the piercing tool  300  can pierce through the separating element abutting the bottom surface  112  when forming an outlet to the container  110 . In another embodiment, the outlet can be formed along the side walls  111  using the second side piercing tool  302 . 
     Referring back to  FIG. 8 , the supporting elements  130  may be independent of the separating elements  120  and  220 , or they may be integral components of the separating element  120  and/or the second separating element  220 . For example, the supporting elements  130  may be a set of a least three members formed integrally with the separating element  120 , extending from the second surface  122  of the separating element  120  at one end to a surface of the second separating element  220  at its other end. 
     Referring to  FIG. 10 , another embodiment of a separating element  320 , supporting elements  330  and second separating element  420  is shown.  FIG. 10  illustrates an example spacer  300  comprising a plurality of walls  310  interconnected with one or more other walls  310 . In this example, the spacer  300  comprises six walls  310  connected at its centre to form a six-spoke star-shape. The supporting elements  330  comprise the walls  310 , the separating element  320  comprises the first surface  321  formed by the top traverse edges of the walls  310 , and the second separating element  420  comprises the second surface  422  formed by the bottom traverse edges of the walls  310 . 
     When the spacer  300  is placed within the container  110 , the separating element  320  or second separating element  420  can be aligned to abut the bottom surface  112  of the container  110 , with the other separating element supporting a pod  140 . The pod  140 , when supported by the separating element  320  or second separating element  420 , is spaced apart from the bottom surface  112  by the height of the walls  310 . The interstitial spaces or gaps defined by adjacent walls  310  serve as drainage passages  323  for enabling fluid communication between the first surface  321  and the second surface  422 . In another example, it will be appreciated that the number of walls  310  can differ from that shown in  FIG. 10  (e.g. three walls  310  forming a three-spoke star-shaped spacer), and the walls  310  can be connected in other configurations to form different cross-sectional shapes of the spacer  300 . One or more walls  310  may also have different thicknesses from other walls  310  and/or be non-uniform along a single wall  310 . It will also be appreciated that the walls  310  can be integrally formed, or individual formed and then attached to other walls  310 . 
     In another embodiment, as shown in  FIGS. 11 and 12 , the supporting element  830  is formed integrally with the container  810 . The supporting element  830  may comprise one or more steps, ledges or protrusions protruding inwardly within the interior space  814 , in the one or more side walls  811  of the container  810 , producing a container within which the smallest diameter of the first portion  815  is greater than the largest diameter of the second portion  816 . The separating element  820 , which may be a disc, has a diameter equal to or slightly smaller than the smallest diameter of the first portion  815  of the container  810  and larger than the largest diameter of the second portion  816  of the container  810 , thereby enabling the separating element  820  to rest on the step between the first and second portions. 
     The container  110  may be formed, typically, by deep drawing or injection moulding, of a heat resistant material which is impervious to water. In one embodiment, the container may be formed in two steps. The side walls  111  and the bottom surface  112  may be formed as a continuous piece, and the lid  113  may later be attached after the separating element  120  and pod have been inserted into the portion of the container comprising the side walls  111  and the bottom surface  112 . 
     The separating element  120  may be formed separately from the container, and of a heat resistant material which is impervious to water. Preferably, the material is also sufficiently rigid to maintain a substantially parallel relationship among the major surfaces  121  and  122  of the separating element  120 , the lid  113 , and the bottom surface  112  of the container  110 , while supporting the weight of both the liquid contained within the first portion  115  of the interior space  114  and the saturated pod  140 , as well as the pressure from the injected liquid. That is, the separating element  120  should not deform under the pressure commonly experienced within the container  110 , but should maintain a consistent relationship between the sides of the first and second portions  115  and  116  of the container  110 , thereby preventing contact with the second piercing tool  300 . The separating element  120  may be positioned on the supporting elements  130  within the container  110 . 
     The lid  113  may be punched from a piercable material and heat sealed or otherwise adhered to the upper edge of the one or more side walls  111  of the container  110 . 
     The cartridge  100  is hence manufactured by providing the separating element  120 , providing the pod  140 , placing the pod  140  on a major surface  121  or  122  of the separating element  120 , and forming the container  110  around the separating element  120  and the pod  140 . 
     In a preferred embodiment, the container  110  is initially only partially formed. For example, the lid  113  may be left unattached. A beverage additive may be placed on the bottom surface  112  of the container  110 . The separating element  120  is placed within the partially formed container  110 , over the beverage additive if present. The pod  140  is placed upon the separating element. The container is then completed by attaching the lid  113  to the side walls  111  thereby enclosing the separating element and the pod. 
     In use, the cartridge  100  is positioned in a beverage making machine, such as a single serving coffee brewer. The machine includes at least two piercing tools  200  and  300 , which are directed towards the cartridge  100 , and operated to create at least one inlet and at least one outlet in the container  110 , in such a way as to provide access to both the first and second portions  111  and  112 . Typically, the cartridge  100  is placed with the machine so that the lid of the cartridge is above the bottom surface of the cartridge, enabling the liquid to flow from the inlet to the outlet by a force at least partially due to gravity. 
     The pod  140  is supported in an advantageous position by the separating element  120 , such that neither the first piercing tool  200  or the second piercing tool  300  contacts the pod  140 . A liquid, water for example, is injected into the first portion  115  of the interior space  114  through an inlet created by the first piercing tool  200 . The water passes through the pod  140  under high pressure and at high velocity, saturating the contents and extracting the aroma and flavour of the contents. Since the pod  140  is supported by the separating element  120 , it is believed that the pod  140  will not tear due to the force of the injected liquid or the force applied on the pod by its own increased weight when saturated. The resulting beverage flows by gravity or another motive force through the drainage passages  123  of the separating element  120 , into the second portion  116  of the container  110 . If a beverage additive has been disposed between the separating element  120  and the bottom surface  112 , the flavoured beverage mixes with the beverage additive. Finally, the beverage additive flows out of the outlet created by the second piercing tool  300 . The beverage may then pass into a beverage collector of some form. 
     In another embodiment, a cartridge  900  is shown in  FIG. 13 , comprising a container  110  that does not contain any separating elements or supporting elements to support a pod  140 , such that the pod  140  can abut and lie on the bottom surface  112  of the container  110 . The absence of separating elements and supporting elements may simplify the manufacturing process and/or costs to make the cartridge  900 . In an example, at least a portion of the outer surface of the pod  140  may be made from material of sufficient resistance to tearing or piercing by a piercing tool (e.g. second piercing tool  300  shown in  FIG. 1 ). In another example, only the portion of the pod  140  facing the bottom surface  112  of the container is made of material resistant to being pierced by the piercing tool. 
     Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the invention.