Patent Publication Number: US-2004055472-A1

Title: One-cup coffee brewer

Description:
BACKGROUND OF THE INVENTION  
       DESCRIPTION OF THE PRIOR ART  
       [0001] There has been a long standing need for a effective and efficient brewer for brewing selected small quantities of coffee such as single servings in a single cup. The demand for single cup coffee brewing has lead to the proposal that small heating devices be provided for heating one cup of water at a time and for spraying through a packet of coffee grind.  
       [0002] Often times, for effective brewing, the initial brew cycle must wet the grind and the hot water then flowed through the grind for an even distribution. Conventional coffee brewers do not typically carry out this function effectively, particularly for flow is to a small quantity of grind, such as that for a single cup of brew.  
       [0003] For the more discriminating customers, the demand for single cup coffee brewing has grown immensely in the past few years. They demand selected flavors of coffee fresh brewed at different times of the day, such as first thing in the morning, on there first arrival at the work place, mid morning or at a scheduled coffee break. The quality of brewed coffee deteriorates rapidly over time. Thus, many discriminating customers will reject coffee which has been brewed sometime previously.  
       [0004] Moreover, with the advent of more discriminating taste, individual preferences dictate a need for coffee which can be brewed in small quantities to satisfy individual tastes. With the numerous variety of flavors and blends currently available, individuals within groups of customers may demand coffee of such different flavors and blend, thus making it impractical to brew a community pot which will satisfy a broad spectrum of individuals in the work place. Consequently, there exists a need for a effective coffee brewing device which will brew small quantities of coffee in a rapid and efficient manner while providing for an effective brew of a flavorful beverage. Devices currently available do not typically provide for positive control of the flow of hot water through the grind packet in such a manner as to assure thorough and complete distribution of water through a packet of grind. The need for relatively uniform flow of water and positive control thereof through the packet becomes more acute with the smaller quantities of grind contained in packets intended for single cup brewing. That is, for the smaller quantities of grind in those packets, the tendency of irrigation passages to be formed to the relatively small quantity of grind in those packets is greater thus creating the risk that portions of the brewing water will pass completely through the packet without effective wash of the grind.  
       [0005] Efforts to provide a single serving or one cup coffee brewing device have led to proposals for a heating bath, dispensing nozzle and some form of non-disposable filter, such as a metal screen of the type which is intended to provide the necessary filtration.  
       [0006] Other efforts have led to the proposal a single cup coffee brewer including a plastic envelope for receiving the coffee grind and a pump for pumping water therethrough under pressure to break a frangible closure exposing a filter through which the brewing liquid is to be flowed.  
       [0007] Traditional single cup coffee brewers typically include a drip filter device. Others have been proposed which include a screw type screen to trap the coffee grind so that hot water may be poured therein and to the screw type screen unscrewed a couple of turns for subsequent introduction of further hot brewing water.  
       [0008] In a somewhat related area, considerable work has been carried out in effort to devise satisfactory espresso coffee brewers. Those devices are typically relatively expensive and often involve high pressure steam, pressure sealing mechanisms and sophisticated mechanisms prone to frequent maintenance problems. Such espresso devices often times involve a piston and cylinder arrangement for trapping the coffee grind in sealed arrangement to force the brewing liquid therethrough for dispensation and to a espresso cup or the like. A device of this type is shown in U.S. Pat. No. 4,421,014 to Vicker.  
       [0009] Other devices have been proposed for brewing espresso coffee which include an automatic turn table formed with apertures for selective receipt of espresso packets to have hot water or steam force therethrough. The turn table is then advanced to forward the aperture to a discharge location where a piston will drive the packet down through the bottom of the turn table. A device of this type is shown in U.S. Pat. No. 5,855,161 to Cortese. These espresso devices are typically relatively expensive to manufacture, require some degree of skill for operation and are prone to maintenance problems. Consequently, they are typically not perceived as acceptable as coffee brewers.  
       [0010] Single cup coffee grind packets are often relatively small and will grow in volume to some degree in volume with the wetting and expansion of the grind. This often creates a risk that the relatively delicate walls the packet may burst under the forces generated by the expansion and growth of such grind. Thus, there exists a need for a single cup coffee brewer which effectively washes the coffee grind even with small volumes of water.  
       SUMMARY OF THE INVENTION  
       [0011] In one aspect of the invention, the one cup brewer of the present invention includes a coffee tower including a brew basket which may be in the form of a brew tray having a perforated horizontal bottom plate for support of a single cup packet of loose coffee grind. A perforated platen rests on the coffee packet and a feed head supplies water to the platen to flow in through the platen perforations to be distributed in a substantially uniform flow pattern through the coffee packet out through perforations in the bottom wall of the tray. In some embodiments the feed water is forced through the perforated platen under pressure to even further enhance performance. The tray may be sized for receiving the packet in close spaced relationship to support the walls of the wetted packet from bursting.  
       [0012] In the preferred embodiment, the platen is biased against the packet so that water through the perforations in the platen is forced to pass in a controlled substantially uniform pattern deep into the packet to flow out holes in the bottom of the tray. The platen may be formed on its bottom side with seals to sealingly engage with the packet to more positively direct water flow into the grind charge contained in the packet to thereby minimize any bypass around the packet. In the preferred embodiment, the platen is carried from the bottom extremity of a vertically shiftable tube and is biased downwardly by a coil spring.  
       [0013] In one embodiment of the invention, the tray is sized for receiving a packet of grind in close fitting relationship to thus provide support about the periphery of the packet to prevent outward bulging of the walls of such pocket which could otherwise result in undue stress on such walls and consequent bursting thereof.  
       [0014] In another embodiment of the present invention, the tray and platen are configured to receive in compressing relationship, a packet of the size which contains a charge of grind sufficient for one cup brewing and the platen tray are formed with an array of water flow holes which dictate distribution of the water in a substantially uniform pattern through the packet such that brewing is thorough.  
       [0015] It will be appreciated by those skilled in art that the brewer of the present invention is particularly adaptable to the brewing of small quantities of coffee such is that required for single cup brewing. The tray is sized and configured such that the platen compresses the packet downwardly into a confined configuration such that the flow of water from the platen, through the packet, and out the tray disbursement openings is controlled for relatively even distribution of the water and efficient and effective brewing of the coffee.  
       [0016] These and other features and advantages of the present invention will become apparent from the following detailed description of a preferred embodiment which, taken in conjunction with the accompanying drawings, illustrates by way of example the principles of the invention. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0017]FIG. 1 is a perspective view of a one cup brewing apparatus of the present invention;  
     [0018]FIG. 2 is a top plan view of the one cup brewing apparatus shown in FIG. 1;  
     [0019]FIG. 3 is a front view of the one cup brewing apparatus shown in FIG. 1;  
     [0020]FIG. 4 is a rear view thereof of the one cup brewing apparatus shown in FIG. 1;  
     [0021]FIG. 5 is a right-hand side thereof of the one cup brewing apparatus shown in FIG. 1;  
     [0022]FIG. 6 is a left-hand side thereof of the one cup brewing apparatus shown in FIG. 1;  
     [0023]FIG. 7 is a partial vertical sectional view, enlarged scale, taken along the line  7 - 7  of FIG. 2;  
     [0024]FIG. 8 is a vertical sectional view taken along the line  8 - 8  of FIG. 7;  
     [0025]FIG. 9 is a vertical sectional view taken along the line  9 - 9  of FIG. 7;  
     [0026]FIG. 10 is a detail view of a tray handle included in the brewer shown in FIG. 7;  
     [0027]FIG. 11 is a partial side view taken along the line  11 - 11  of FIG. 9;  
     [0028]FIG. 12 is a horizontal sectional view taken along the line  12 - 12  of FIG. 7;  
     [0029]FIG. 13 is a horizontal sectional view taken along the line  13 - 13  of FIG. 7;  
     [0030]FIG. 14 is a partial vertical sectional view similar to FIG. 7 showing the platen in its raised position;  
     [0031]FIG. 15 is a vertical sectional view taken along the line  15 - 15  of FIG. 14; and  
     [0032]FIG. 16 is a diagramatic view of a second embodiment of the beverage brewing apparatus of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
     [0033] The one cup coffee brewer of the present invention includes, generally, a brewing apparatus in the form of a brewer  21  (FIG. 1) having a base  23  configured with a forwardly projecting table  25  disposed under an over hang  27  which mounts a tray hanger  30  carrying a coffee packet holder in the form of a tray assembly  29 . Referring to FIG. 7 and  8 , and still speaking generally, the tray assembly  29  includes a tray device  31 , for receipt of a one cup packet  33 , of coffee grind  37  to be pressed under a platen  41 . The tray device  31  includes a false bottom defining a distribution plate  45  configured with a pattern of through openings  47  which cooperate with a pattern of through openings  51  in the platen  41  to direct hot water from a feed head, generally designated  55 , through such holes  51 , through the packet  33  and out such distribution wall  45  to be gathered in a cup  57  (FIG. 7).  
     [0034] The brewing apparatus  21  may be in the form of a brewing tower having a heat sink tank  61  for connection to a water supply to receive and store water to be heated. A hot water spigot  63  is typically connected with a water tank by a mounting tube  65  for drawing off of hot water for tea or the like. A heating coil is typically submerged in the tank  61  and may have its outlet connected with a flexible supply tube  71  (FIG. 7) for supplying hot water to brew the coffee.  
     [0035] The overhang  27  may mount a brewing basket, funnel or other device acting as a tray for receiving and holding the coffee packet  33 . As referred to herein, the term tray and tray device is intended to encompass all such equivalents.  
     [0036] Referring to FIG. 7, the brewer  21  includes a downwardly opening hood, generally designated  87  disposed on the over hang  27  in alignment over the tray. The hood  87  is formed in the forward section of its top wall with a bore  93  through which a vertical retractor plunger stem  95  projects to terminate in a head  96 . Mounted to the bottom end of such stem  95  is a vertical feeder tube  97 . Such tube is formed in its side wall with a threaded bore  99  into which a nipple  101  is threaded for connection to the flexible water supply tube  71 . The tube  97  is telescoped through an axial bearing  105  mounted in a bore formed in the top wall  107  of the overhang to project downwardly and be formed at its bottom extremity with an outwardly flared flange  109  that mounts a plenum bonnet  111 . Such bonnet  111  is in the form of an inverted cup but elongated horizontally to form a plenum chamber  113  sized and configured to capture thereunder the pattern of disbursement bores  51  formed in the platen  41 .  
     [0037] Received in telescopical relationship over the tube  97  and interposed between the bearing  105  and the bonnet  111  is a coil compression spring  121  which, in its extended position shown in FIG. 7, exerts a force of about one pound downwardly on the bonnet and consequently the platen  41 . Referring to FIG. 8, mounted under the overhang is channel shaped hanger configured on its bottom extremity in-turned lips  128  defining a track for slidably receiving the tray device.  
     [0038] Referring to FIGS. 7 and 12, the tray device  31  is formed with a collector bottom wall  75  upwardly turned front back and side walls  121 ,  123 ,  125  and  127  (FIG. 12) configured to receive in close fitting relationship the periphery of the coffee grind packet  33  (FIGS. 7 &amp; 8). In a preferred embodiment, the tray is approximately 2½″ inches wide and 3½″ inches long. The coffee grind packet  33  may be custom made to closely fit the interior of the tray and be retained by the side, back and front walls thereof to be supported against outward spreading thereof in the lateral and forward rearward directions. The tray itself is in the preferred embodiment, constructed with the collector bottom wall  75  lined by the false bottom distribution plate  45  and formed centrally with an elongated trough  77  leading to a downwardly opening funnel shaped dimple  79  terminating in a outlet opening  81  centered over the container  57 .  
     [0039] Referring to FIG. 7 mounted on the front of the tray is an L shaped angel handle  151  which is thermally insulated from such handle by means of a thermal insulation strip  153  to minimize heat transfer from the tray to the handle.  
     [0040] In the preferred embodiment, the distribution plate  45  is a metallic plate serving as a false bottom in the tray and formed at its forward extremity with an upturned tongue  131  forming the forward wall of the tray compartment and turned back to form a rearwardly projecting lip  133  underneath which the forward extremity of packet  33  may be trapped as shown in FIG. 7. The rearward corners of such plate may be turned down slightly to contact the bottom wall  75  of the tray to cooperate in spacing the body of such plate about {fraction (1/64)}″ above such bottom wall for ready flow of brewed water under the plate to collect in the trough  77  (FIG. 7 &amp; 8).  
     [0041] As will be appreciated by those skilled in the art, the platen  41  itself may take many different shapes and forms such as rectangular, triangular, circular, oval or any other convenient shape. In the exemplary embodiment, the platen is shown in plan view in FIG. 13 rounded at its forward end and formed with its opposite sides tapering inwardly and rearwardly toward one another. Preferably, such platen is formed with downwardly depressed funnel shaped dimples  52  concentric with the openings  51  to terminate at their respective bottom ends in circular edges which are pressed into the top side of the packet to sealingly engage therewith.  
     [0042] As shown in FIG. 12, the disbursement plate  45  is formed with the holes  47  arranged in a pattern defining three longitudinal rows of four, spaced laterally apart. The pattern of holes  51  in the platen  41  are also arranged in a rectangular pattern with three on a side such that when disposed in compressing relationship over the packet  33  the water flowing through such holes will, while being disbursed through the coffee bean grind, tend to flow in a disbursement pattern which is generally rectangular and will flow through and through the outlet disbursement holes  47  such that the generally rectangular pattern of the arrangement of holes cooperate to maintain a generally rectangular overall pattern of flow which compliments the rectangular shape of the packet  33  and the rectangular tray  31 .  
     [0043] As it will be appreciated by those skilled in the art the pattern of holes in the platen  41  and disbursement wall  45  may take many different shapes and forms, it only important that they cooperate together to facilitate a relatively thorough wash of the grind in the packet  33 . As an example, if the tray where in a form of a circular or oval basket, it would be preferred that the holes be likewise arranged in a circular or oval pattern as the case may be.  
     [0044] Mounted to the rear of the hanger  31  in the exemplary embodiment is a platen catch device, generally designated  161  (FIG. 14 and  15 ) for selectively catching the platen and holding in an elevated position. Such catch device includes a laterally projecting pivot strip  165  terminating at its opposite ends in respective tangs  167  for receipt in respective bores  164  (FIG. 9 and  11 ) formed in the opposite side walls of the hanger  31 . Mounted on the front side of such pivot strip  165  and disposed centrally thereon is an upright catch post  171  which is weighted to tilt forwardly at the top. The post is formed on its front edge with an upwardly and rearwardly angled cam surface  172  disposed in the path of the tray. Such rearwardly inclined cam surface  172  terminates at its upper end in a notch  173  configured with a upwardly facing shoulder  175  which, when the top end of the post is tilted forward as shown in FIG. 14, is disposed in the vertical path of the platen to engage under the rear extremity to hold such platen in its elevated position shown in FIG. 14 above the top extremity of the tray.  
     [0045] Mounted in the tank  61  is conventional plumbing and electrical circuitry (not shown), including control circuitry having an on/off switch  174  (FIG. 4) and a central processing unit (CPU) which is operative to actuate a heater to heat the water bath and maintain such baths at an elevated temperature. Conveniently, the control circuit includes a start switch connected with a vertical plunger rod  181  (FIG. 1) connected with one end of a control handle  183  carried from a fulcrum clevis  185  and having a handle grip  187  on the free extremity thereof. As will be appreciated, such handle simulates a pump handle.  
     [0046] In operation, the coffee brewer of the present invention may be powered by actuating the on/off switch  174  to actuate the control circuitry and energize the CPU and consequently, the water heater. Once the water is heated, the brewer is ready for the brewing process.  
     [0047] The head  96  of the plunger stem  95  carrying the inlet tube  97  may be drawn upwardly to raise the platen  41  to the elevated position shown in FIG. 14. It will appreciated that the rear edge of such the platen  41  will ride upwardly on the cam surface  172  of the catch post to the point where the platen is of the same elevation as the shoulder  175 , at which time such post  171  will tilt further forwardly at the top extremity to the position shown in FIG. 14 thus engaging such shoulder under the rear edge of such platen to hold it in its elevated position. The handle  151  of such tray may be grasped and to draw the tray forwardly out from under the platen to clear the hanger  31  and, if desired, be removed clear of the hanger. A grind packet  33  may then be selected and inserted in the tray itself. The tray may then be reintroduced under the platen by sliding it into the hanger  31  to shift it rearwardly under the platen causing the rear end thereof to engage the cam surface  172 . Then as the tray is pushed further rearwardly, the post  171  will be rotated in the clockwise direction as viewed in FIG. 14 about the pivot axis defined by the tangs  167  (FIG. 15) thus driving the upper extremity of the post rearwardly to the position in FIG. 7. As the tray reaches the point when it is aligned under the platen the post will have been rotated rearwardly to the point wherein once the shoulder  175  clears the rear edge of such platen to free it to be driven downwardly onto the packet  33  by gravitational force combined with the spring  121 . This then serves to press the packet firmly in place in the tray with the grind having a depth of about, as an example ⅛″.  
     [0048] The handle  183  may then be actuated by pressing downwardly on the grip  187  to raise the actuating plunger  181  to close the actuation switch to communicate pressurized water through a conventional heat exchange coil and out the flex tube  171  into the feed tube  97  (FIG. 7). Such water will then flow downwardly in such tube into the plenum chamber and through the platen openings  41 . As the water pump fills up the pressure in such plenum chamber, the water will be forced downwardly through the grind in the packet  33  from where it will seek to escape via the pattern of disbursement holes  47  in the distribution wall  45 .  
     [0049] It will be appreciated the weight of the platen, feeder tube and the force of the coil spring  121  will serve to force the platen downwardly thus driving the bottom ends of the dimples  52  positively into the top wall of the packet  33  thus forming respective seals therewith such that disbursing water is forced into the packet thereby preventing escape across the top surface of the packet which may otherwise result in bypass of the grind within such packet. The water will be forced through a series of tributary—like flow paths, circulating about the grinds in a relatively uniform flow pattern to escape out the openings in the distribution platen to be gathered thereunder and flow down the trough to the outlet opening  81 . It will also be appreciated that the platen may be turned downwardly at its peripheral edges to form a peripheral seal to cooperate with the dimples  52  or, in lieu thereof, to cooperate in directing water into the packet.  
     [0050] As will be appreciated by those skilled in the art, the rectangular pattern of the flow from the platen holes  51  will be directed to a great extent in a rectangular pattern uniformly through the packet toward the rectangular pattern of holes  47  in the distribution plate thus providing for positive washing of the grind within the packet  33 . Obviously, some of the hot water will concurrently flow to the other areas of the grind within such packet thus resulting in a relatively effective and complete wash of flavor from such grind.  
     [0051] As the grind is wetted it will expand thus enlarging the overall volume of the grind within the packet causing the volume of the packet itself to grow. As the volume of grind grows, the walls of the tray will support peripheral walls of the packet against lateral and forwardly and rearwardly expansion thus providing support against the walls of the packet themselves bursting the increased volume. Meanwhile, the spring  121  will accommodate such growth allowing the platen  33  to be raised as the volume of the grind grows thereby minimizing any tendency of the growth to place excess stress on the packet and burst the walls of the packet but still maintaining a positive pressure downwardly on the platen to maintain effective sealing engagement between such platen and the top surface of the packet.  
     [0052] A control meter within the flow circuit will control flow of the water to efficiently and effectively extract the desired flavoring from the grind and fill the coffee cup  57 . When a sufficient volume of water has been dispensed to fill the cup  57 , or other container selected, to the desired level, the flow control meter will close the control valve in the plumbing to discontinue flow. The user may then remove the cup and enjoy a helping of freshly brewed coffee.  
     [0053] The plunger head  96  may then be grasped to raise the feeder tube  97  and consequently the platen  33  to free the tray to be removed for removable of the spent packet  33 . The next user may then insert a new packet of coffee of the desired flavor and promptly repeat the process. As will be appreciated by those skilled in the art, the reserve of heat in the water within the tank  61  will typically provide sufficient heat to provide eight to ten cups of water to be consecutively drawn from the heat exchange tube in rapid succession without any extensive delay in time for reheating of the water bath. This then allows for the brewer to typically stand ready for dispensing of water for efficient and effective brewing of the coffee.  
     [0054] The brewing apparatus of the present invention may take many different forms. The device may be incorporated, in, for instance, a claim actuated coffee dispenser where the basket for tray is mounted over a cup table which will receive a dispensed cup since the apparatus may include an automatic packet dispenser which is responsive coins, bills, or credit cards or the like of the selected denomination to dispense a selected packet into the tray or basket and the platen automatically lowered into position constraining the packet within the tray. Further, it will be recognized that the feed head formed by the plenum chamber and platen holes  51  may take many different forms, including an open feed head to spray water under gravity flow for flowing through the packet and trapped under the platen or any other desirable configuration known to those skilled in the art or which may be developed in the future.  
     [0055] The shape and construction of the tray holding device and the tray itself may also take many different forms. The tray holding device may be in the form of a hanger, hook, plate or any other desired support. The tray may be in the form of a basket or any other coffee packet holding mechanisms presently known to those working in the art or which might be developed in the future. It will be appreciated that the size and the shape of the tray itself may take many different forms. It maybe eleptical, cylindrical or any other desired shape to facilitate efficient brewing from the coffee bean grind. The shape and configuration of the platen may also vary. The holes in the platen may vary shape, configuration and in their pattern. As an example, the holes may be arrayed in a eleptical, round or any other desired pattern such as FIG. “ 8 ” to provide for efficient disbursement of the water forced to spray therethrough. While there is benefit to the pattern of holes in the platen complimenting the horizontal shape of the tray and the pattern of the holes in the false bottom thereof, such pattern may vary in many different configurations that will be apparent to those skilled in the art and which will be effective to provide for efficient and effective brewing. Such holes may be formed by corregations, grooves or other fluid dispensing structure which will serve to provide for preferential release of the brewed fluid from the packet from disbursed points and locations across the bottom of the packet. The term distribution holes used here is intended to encompass plates with all such constructions, whether acting as the bottom wall for the tray opening directly downwardly on a decanter or cap or as a false bottom as specifically described herein.  
     [0056] The coffee brewer apparatus shown in FIG. 16 is similar to that set forth in FIGS.  1 - 15  except that it is a smaller model and includes a flow through heating device. The apparatus, generally, includes a housing or cabinet  201  which houses a water heater tube  203  that is about 2 inches in diameter and about 8 inches long. The heater tube  203  forms a cylindrical water tank and in which is mounted a heating coil  207  connected in circuit with the control switch  174 . The tube  203  holds about 8 ounces of water and the heating coil  207  produces about  1800  watts of heat to thus maintain the water at about 200°. It has been found that the device will brew a generous cup of coffee in approximately one minutes time. The pressurized water line is connected with the heating tube  203  through a control valve  213  controlled by a push button control  215  to control flow through meter  217  into the inlet of such heating tube  203 . The outlet of such heating tube is connected to the tube  65  to the spray head  63 .  
     [0057] With this apparatus, when it is desirable to brew a single cup of coffee, the switch button  215  may be depressed to actuate the valve  213  an open such valve for a selected period of time as dictated by a controller (not shown) to introduce pressurized water and to the heater tube  203 . Such pressurized water will replace a volume of heated water corresponding with the volume of a cup  57  causing such heated water to be driven through the tube  65  for flow through the grind packet and dispersing openings.  
     [0058] From the foregoing it would be apparent that the coffee brewing apparatus and method of the present invention provide a highly effective means for efficiently extracting a flavor from coffee grind to make full use of the grind while providing for rapid brewing.  
     [0059] While a particular form of the invention has been illustrated and described, it will also be apparent to those skilled in the art that various modifications can be made without departing from the spirit and scope of the invention. Accordingly, it is not intended that the invention be limited except by the appended claims.