Patent Abstract:
A brewed beverage appliance uses a specialized pre-packaged beverage container and a related method of brewing a beverage. The container comprises a cup-shaped base having openings at the bottom. A plurality of roasted, whole coffee beans are contained therein. The appliance has a blade that punctures the cup and then grinds the beans while they are still in the cup. Heated water is delivered to the cup and passes through the ground coffee causing brewed coffee to emit from the openings in the bottom of the cup and into a container such as a coffee mug.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application Ser. No. 61/413,744, filed on Nov. 15, 2010, which is herein incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to brewed beverage appliances and, more particularly, to a brewed beverage appliance adapted to brew coffee from a pre-packaged, disposable container and filter combination. 
       BACKGROUND OF THE INVENTION 
       [0003]    Various known coffee making appliances involve adding of coffee beans in one of various forms (i.e., ground or unground) to a container that is part of a machine in which heated water is delivered to the container and passes therethrough. The container typically includes a filtering mechanism so that heated water exiting the container is in the form of brewed coffee. Certain appliances require pre-ground coffee beans to be added in the form of “grounds.” Other appliances are designed to accept whole coffee beans into a hopper or opening and include mechanisms that grind the beans into a ground form and then complete the brewing process. It is sometimes preferred to keep whole beans on hand for making coffee so that the coffee may be ground immediately prior to brewing, as this is believed to produce the freshest tasting coffee beverage. Yet other appliances required use of pods or pre-packaged coffee grounds in a serving-sized filter container to be inserted into the appliance. In such instances, the pre-packaged pods or containers are limited to being filled with ground coffee. Certain pre-packaged containers require placement into a separate filter mechanism in the appliance, while others have built-in filtering mechanisms. 
       SUMMARY OF THE INVENTION 
       [0004]    It is an object of the present invention to provide a beverage making appliance and related method that include the benefits of brewing coffee from whole beans that are ground immediately before brewing and that are contained in a convenient, disposable, single-serving package. 
         [0005]    These and other objects are achieved by the present invention. 
         [0006]    A coffee making appliance in accordance with the present invention is directed to an appliance, a specialized pre-packaged coffee container and filter, and a related method of brewing coffee using the same. The container comprises a cup-shaped base having a large opening at the top, a circumferential sidewall, and a floor with grooves to direct fluid flow to an opening at the bottom. A paper filter is located on the floor of the cup and on top of the paper filter is a screen. Both the paper filter and the screen are circular and sized to fit across the entire surface area of the floor. A plurality of roasted, whole coffee beans are positioned on top of the screen and the cup is sealed with a lid of foil so that the beans are contained therein. The appliance has mechanisms such that when the cup is positioned in a compartment within the appliance and the appliance is activated, a blade assembly punctures the foil and enters the cup, and then grinds the beans while they are still in the cup. Next, heated water is delivered to the cup and passes through the grounds, causing brewed coffee to emit from the opening in the bottom of the cup and into a container. The size of the cup and the amount of heated liquid delivered will result in the size of the coffee serving, such as a single cup or a pre-selected size that is greater. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is an exploded view of a whole coffee bean pre-packaged filter cup according to the present invention. 
           [0008]      FIG. 2  is a perspective top view of the whole coffee bean pre-packaged filter cup of  FIG. 1 . 
           [0009]      FIG. 3  is a perspective bottom view of the whole coffee bean pre-packaged filter cup of  FIG. 1 . 
           [0010]      FIG. 4  is a top plan view of the whole coffee bean pre-packaged filter cup of  FIG. 1 . 
           [0011]      FIG. 5  is a bottom plan view of the whole coffee bean pre-packaged filter cup of  FIG. 1 . 
           [0012]      FIG. 6  is a side elevational view of the whole coffee bean pre-packaged filter cup of  FIG. 1 . 
           [0013]      FIG. 7  is a side cross-sectional view of the whole coffee bean pre-packaged filter cup of  FIG. 1  taken along line A-A of  FIG. 6 . 
           [0014]      FIG. 8  is an exploded view of a whole coffee bean pre-packaged filter cup according to another embodiment of the present invention. 
           [0015]      FIG. 9  is a perspective right side view of a coffee appliance according to the present invention. 
           [0016]      FIG. 10  is a perspective left side view of the coffee appliance of  FIG. 9 . 
           [0017]      FIG. 11  is a left side elevational view of the coffee appliance of  FIG. 9 . 
           [0018]      FIG. 12  is a front elevational view of the coffee appliance of  FIG. 9 . 
           [0019]      FIG. 13  is a right side elevational view of the coffee appliance of  FIG. 9 . 
           [0020]      FIG. 14  is a rear elevational view of the coffee appliance of  FIG. 9 . 
           [0021]      FIG. 15  is a top plan view of the coffee appliance of  FIG. 9 . 
           [0022]      FIG. 16  is a bottom plan view of the coffee appliance of  FIG. 9 . 
           [0023]      FIG. 17  is a perspective view of the coffee appliance of  FIG. 9  illustrating a ready mode thereof. 
           [0024]      FIG. 18  is a perspective view of the coffee appliance of  FIG. 9  illustrating the loading of the whole coffee bean pre-packaged filter cup of  FIG. 1 . 
           [0025]      FIG. 19  is a perspective view of the coffee appliance of  FIG. 9  illustrating the whole coffee bean pre-packaged filter cup of  FIG. 1  in a loading tray. 
           [0026]      FIG. 20  is a perspective view of the coffee appliance of  FIG. 9  in a loaded state. 
           [0027]      FIG. 21  is a perspective view of the coffee appliance of  FIG. 9  in a brew-ready state. 
           [0028]      FIG. 22  is a perspective view of the coffee appliance of  FIG. 9  during brewing/operation. 
           [0029]      FIG. 23  is a perspective view of the coffee appliance of  FIG. 9  subsequent to brewing a cup of coffee. 
           [0030]      FIG. 24  is a perspective view of the coffee appliance of  FIG. 9  illustrating the removal of a spent pre-packaged filter cup subsequent to brewing. 
           [0031]      FIG. 25A  is a schematic view of the whole coffee bean pre-packaged filter cup of  FIG. 1  illustrating water flowing through during a brewing mode. 
           [0032]      FIG. 25B  is a bottom plan view of a shower head for distributing heated water to the whole coffee bean pre-packaged filter cup of  FIG. 1  in accordance with the present invention. 
           [0033]      FIG. 26  is a first, side cross-sectional view of the coffee appliance of  FIG. 9  in a first mode. 
           [0034]      FIG. 27  is a second, side cross-sectional view of the coffee appliance of  FIG. 9  in a first mode. 
           [0035]      FIG. 28  is a first, side cross-sectional view of the coffee appliance of  FIG. 9  shown in a second mode. 
           [0036]      FIG. 29  is a second, side cross-sectional view of the coffee appliance of  FIG. 9  shown in a second mode. 
           [0037]      FIG. 30  is a detail schematic view of a grinding motor and grinding blade assembly of the coffee appliance of  FIG. 9 . 
           [0038]      FIG. 31  a cross-sectional, schematic view of the coffee appliance of  FIG. 9  in a mode of operation. 
           [0039]      FIG. 32  a cross-sectional, schematic view of the coffee appliance of  FIG. 9  in another mode of operation. 
           [0040]      FIG. 33  a cross-sectional, schematic view of the coffee appliance of  FIG. 9  in another mode of operation. 
           [0041]      FIG. 34  is an enlarged, detail view of a filter cup lifting mechanism and grinding motor of the coffee appliance of  FIG. 9 . 
           [0042]      FIG. 35  is an enlarged, cross-sectional, schematic view of the coffee appliance of  FIG. 9  in a mode of operation. 
           [0043]      FIG. 36  is an enlarged, cross-sectional, schematic view of the coffee appliance of  FIG. 9  in another mode of operation. 
           [0044]      FIG. 37  is an enlarged, cross-sectional, schematic view of the coffee appliance of  FIG. 9  in a mode of operation. 
           [0045]      FIG. 38  is a perspective view of a grinding blade assembly for use with the coffee appliance of  FIG. 9 , in accordance with the present invention. 
           [0046]      FIG. 39  is a top plan view of the grinding blade assembly of  FIG. 38   
           [0047]      FIG. 40  is a left side elevational view of the grinding blade assembly of  FIG. 38 . 
           [0048]      FIG. 41  is a front elevational view of the grinding blade assembly of  FIG. 38 . 
           [0049]      FIG. 42  is a right side elevational view of the grinding blade assembly of  FIG. 38 . 
           [0050]      FIG. 43  is a side cross-sectional view of grinding blade assembly of  FIG. 38 , taken along line A-A of  FIG. 41 . 
           [0051]      FIG. 44  is a schematic view of a blade assembly and the whole coffee bean pre-packaged filter cup of  FIG. 1  shown in a first position. 
           [0052]      FIG. 45  is a schematic view of a blade assembly and the whole coffee bean pre-packaged filter cup of  FIG. 1  shown in a second position. 
           [0053]      FIG. 46  is a schematic view of a blade assembly and the whole coffee bean pre-packaged filter cup of  FIG. 1  shown in a third position. 
           [0054]      FIG. 47  is a schematic view of a blade assembly and the whole coffee bean pre-packaged filter cup of  FIG. 1  shown in a fourth position. 
           [0055]      FIG. 48  is an enlarged schematic view of the coffee appliance of  FIG. 1  in a grinding mode. 
           [0056]      FIG. 49  is a cross-sectional view of the coffee appliance of  FIG. 1  in a grinding mode, taken along line B-B of  FIG. 48 . 
           [0057]      FIG. 50  is an enlarged schematic view of the coffee appliance of  FIG. 1  subsequent to grinding coffee beans. 
           [0058]      FIG. 51  is an enlarged schematic view of the grinding blade of the coffee appliance of  FIG. 1  grinding a coffee bean according to the present invention. 
           [0059]      FIG. 52  is a perspective front view of an alternative grinding blade assembly for use with the coffee appliance of  FIG. 9 , in accordance with another embodiment present invention. 
           [0060]      FIG. 53  is a perspective rear view of the alternative grinding blade assembly of  FIG. 52 . 
           [0061]      FIG. 54  is a top plan view of the alternative grinding blade assembly of  FIG. 52 . 
           [0062]      FIG. 55  is a left side elevational view of the alternative grinding blade assembly of  FIG. 52 . 
           [0063]      FIG. 56  is a front elevational view of the grinding blade assembly of  FIG. 52 . 
           [0064]      FIG. 57  is a right side elevational view of the grinding blade assembly of  FIG. 52 . 
           [0065]      FIG. 58  is a schematic, cross-sectional view of the coffee appliance of  FIG. 9  illustrating a flow of water from a reservoir through the pre-packaged filter cup of  FIG. 1 . 
           [0066]      FIG. 59  is a schematic, cross-sectional view of the coffee appliance of  FIG. 9  illustrating a cleaning mode. 
           [0067]      FIG. 60  is a perspective view of a water reservoir of the coffee appliance according to the present invention. 
           [0068]      FIG. 61  is a bottom plan view of a portion of the coffee appliance of  FIG. 9   
           [0069]      FIG. 62  is a perspective view of a tray for receiving the whole coffee bean pre-packaged filter cup of  FIG. 1 . 
           [0070]      FIG. 63  is a side, cross-sectional view of the tray of  FIG. 62 . 
           [0071]      FIG. 64  is a bottom plan view of the tray of  FIG. 62 . view of a tray component of an appliance according to the present invention. 
           [0072]      FIG. 65  is a perspective view of a coffee appliance having a slidable drip tray according to the present invention. 
           [0073]      FIG. 66  is a cross-sectional view of the coffee appliance of  FIG. 65  showing the slidable drip tray in an extended position. 
           [0074]      FIG. 67  is a cross-sectional view of the coffee appliance of  FIG. 65  showing the slidable drip tray in a retracted position. 
           [0075]      FIG. 68  is a schematic view of a coffee appliance according to another embodiment of the present invention. 
           [0076]      FIG. 69  is a schematic view of a coffee appliance in accordance with another embodiment of the present invention, illustrating a grinding motor in a first position. 
           [0077]      FIG. 70  is a schematic view of the coffee appliance of  FIG. 69  illustrating the grinding motor in a second position. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0078]    Referring to  FIGS. 1-7 , a filter cup  10  for use with an appliance according to the present invention includes a cup  12 , a paper/fabric filter  14 , a plastic screen  16  and a foil cover  18 . The filter  14  prevents coffee grounds and other sediment from exiting the cup  12  during brewing but permits passage of liquid. The cover  18  may be formed from aluminum or other material known in the art, and is preferably heat-sealed or otherwise releasably affixed to the top rim of the cup  10 . A plurality of whole coffee beans  20  are enclosed in the space between the foil cover  18  and the plastic screen  16 . While  FIG. 1  shows coffee beans housed in the filter cup  10 , other types of food and substances, such as tea and the like, may be used in similar fashion to that described herein, without departing from the broader aspects of the present invention. 
         [0079]    As further shown in  FIG. 1 , the cup  12  has an opening  22  at the top thereof, a circumferential sidewall  24  and a floor  26 . As best shown in  FIGS. 2-7 , the floor  26  has a plurality of grooves or channels  28  that direct a flow of fluid to a circular depression or recess  30  having one or more apertures  32 . Importantly, the recess  30  is the lowest portion of the cup  10  such that brewed coffee collects in the recess  30  and exits the cup through the apertures  32 , as discussed hereinafter.  FIG. 7  illustrates the cup  10  in an assembled state and containing coffee beans  20 . As shown therein, the paper filter  14  is positioned on the floor  26  of the cup  12 . The plastic screen  16  is positioned on top of the paper filter  14  and protects the paper filter  14  from abrasion caused by a grinding blade and/or coffee grounds. Both the paper filter  14  and the screen  16  are circular and sized to be closely received by the circumferential sidewall  24  of the cup at the bottom thereof. As best shown in  FIG. 7 , the screen  16  may be resilient and resistant to bending such that the screen  16  provides a flat surface in the cup  12  on top of which coffee bean  20  may rest. Importantly, the screen  16  prevents the coffee beans  20  from falling to the floor  26  of the cup  12  (which may be out of reach of a grinding blade) to facilitate optimal grinding by the grinding blade, as discussed in detail hereinafter. As discussed above, the foil cover  18  seals the filter  14 , screen  16  and coffee beans  20  inside the cup  12 . 
         [0080]    The cup  10  may be stored and transported in a separate sealed package or wrapper for additional freshness and protection, and the apertures  32  in the floor  26  may be covered with, for example, an adhesive label (not shown). In the preferred embodiment, the filter cup  10  is a pre-packaged, single-use, disposable component. Thus, it is sealed by the foil cover  18  in an air-tight manner to preserve freshness and flavor and to protect the coffee beans  20  from moisture and contamination. As discussed above, the filter cup  10  may be sealed by the foil cover  18  and an adhesive label, or may be packaged in a wrapper with or without the adhesive label. In an alternative embodiment, it is contemplated that the filter cup  10  may instead be a re-usable cup that is re-filled for each use. In an embodiment, the floor  26  of the cup may be formed without apertures  32 . In this embodiment, the floor of the cup  26  may be pierced by a needle upon insertion into a coffee appliance to provide an exit for the flow of brewed coffee. 
         [0081]    Referring now to  FIG. 8 , an alternative construction of a filter cup  50  is shown. As shown therein, the cup  50  is substantially similar in shape and construction as the cup  10 , however, a metal mesh filter  52  may be utilized in place of the paper/fabric filter  14  and the protective plastic screen  16 . In this embodiment, the metal mesh filter  52  is fine enough such that it prevents coffee grounds from exiting the cup  10  and also provides a level of abrasion resistance. While it is disclosed that the filter  34  may be formed from a metal mesh, other materials substantially resistant to abrasion from the grinding blade and/or coffee grounds may also be utilized without departing from the broader aspects of the present invention. 
         [0082]    Referring to  FIGS. 9-24 , an appliance  100  according to an embodiment of the present invention is shown. The appliance  100  is intended to be used in combination with the filter cup  10 , disclosed above, in order to brew a coffee or other beverage. As shown therein, the appliance  100  is generally rectangular in shape and comprises a base  102  and a drip tray housing  104  slidably receiving a drip tray  106  having a slotted or grated top surface  108 . The surface  108  of the tray  106  is adapted to have a container, such as a coffee mug  109 , placed upon it to receive brewed coffee as it is produced by and emitted from the appliance  100 . As will be readily appreciated, the slotted surface  108  permits liquid that may be spilled from the cup  109  or that miss the cup  109  during operation to pass through the surface  108  and collect in the drip tray  106 , for easy cleanup. 
         [0083]    A housing  110  is located above, and supported by, the base  102  and slidably receives a grinding platform such as a filter cup housing/tray  112  for securing and positing the filter cup  10  during use. A handle  114  is pivotally mounted to the housing  110  for operation, as described below. As further shown in  FIGS. 9 and 10 , a water reservoir  116  is attached to, supported by, and otherwise forms a part of the housing  17 . In an embodiment, the water reservoir  116  may be removably or permanently mounted to the housing  110 . The housing  110  also includes a control panel  118  for controlling operational features of the appliance, as discussed hereinafter. As best shown in  FIG. 9 , the base  102  includes a recess on one side there for slidably receiving a discard tank  120  for receiving water from a cleaning operation of the appliance  100  (described below) and discarded filter cups  10  after use. In an alternative embodiment, the tray  112  may be pivotally received by the housing  110  and movable between a first position in which the housing/tray  112  is received within the housing, and a second position in which the tray  112  is pivoted away from the housing and towards a user to facilitate the installation of a filter cup  10 . In an embodiment, the tray  112  is removable from the housing  110  for cleaning. 
         [0084]    Operation of the appliance  100  will now be described with specific reference to  FIGS. 17-24 . First, the water reservoir  116  is filled with water. A user then selects the desired coffee settings from the control panel  118 . Settings may include selectable options such as coffee strength and serving size, timer setting, automatic brew, etc. The handle  114  is then moved upwardly in the direction of arrow A, as shown in  FIG. 17 , in order to unlock the tray  112  from its seated and retained position within the housing  110 . The tray  112  slides out from the appliance  100  in the direction of arrow B to the position shown in  FIG. 18 , under force of a spring  154 . In this position, the tray  112  is ready for a filter cup  10  to be placed into the receiving bracket  124  in the tray  112 . 
         [0085]    After the cup  10  is inserted into the tray  112 , the tray  112  is now ready to be pushed back into the appliance  100  in the direction of arrow C, as shown in  FIG. 19 . In particular, the tray  112  is pushed manually back into the appliance  100  so that it is received by the housing  110  in locked position, as shown in  FIG. 20 . The handle  114  is then lowered in the direction of arrow D in order to automatically initiate the grinding and brewing processes. 
         [0086]    Referring to  FIG. 21 , as noted above, the grinding process starts automatically after the handle  114  is lowered. In the process, the coffee beans  20  in the filter cup  10  are ground by a grinding blade  126  that is received within the cup  10  so that the beans  20  are turned into coffee grounds  128 . After grinding is completed, heated water is delivered into the cup  10  from a water outlet described hereinafter. As represented by the arrow  130  in  FIG. 22 , coffee is emitted from the bottom of the tray  112 , which has an opening to enable such emission, into the coffee mug  109  positioned beneath the tray  112 . 
         [0087]    After the brewing process is complete, the handle  114  is raised from the position shown in  FIG. 23  in the direction of arrow E to the position shown in  FIG. 24 . Again, movement of the handle  114  to its upper position unlocks the tray  112  so that it slides out of the housing  110  appliance  100 , permitting the user to manually remove the used filter cup  10  from the tray  112 . The cup  110  may then be discarded into the discard tank  120 . The filled mug  109  of coffee may be removed from the drip tray  106  before or after this step. 
         [0088]    In an embodiment, while the tray  112  is in the out position, as shown in  FIG. 24 , a blade cleaning operation automatically begins. In the blade cleaning operation water is emitted from the water outlet  132 . Because the cup  10  has been removed, the blade is surrounded by space thereby enabling the flowing water to rinse it clean. In an embodiment, the blade may rotate during application of water to facilitate cleaning. Since the tray  112  is in the out position, the water will not drain out of the bottom of the cup  10  and tray  112 , as it does in the brewing mode. Instead, the water is diverted because it falls into the rear end  134  of the tray  112  into a collection pan  136 , as is shown in  FIG. 59 . The water exits from the collection pan  136  of the tray  112  via a discard tube  138  and falls into the discard tank  120 . 
         [0089]    In an alternative embodiment, a cup containing a cleaning liquid such as water may be utilized to clean the blade  166  either periodically or after each use. In this embodiment, a cleaning cup is inserted into the receptacle  124  and the appliance  100  is actuated by pulling the handle  114  downward. The appliance  100  may then run a normal brewing cycle. Alternatively, a button on the control panel  118  may be depressed to run a cleaning cycle. The cleaning cycle may be specifically configured, e.g., water temperature, run time, blade rotation speed, to optimize blade cleaning and sterilization. In alternative embodiments, the cleaning cup may contain a cleaning solution or a slurry of cleaning ingredients. The cleaning ingredients may be liquid or dry and may take the form of granules, powder, etc. 
         [0090]    In yet another embodiment, a cleaning operation may including running a brewing cycle without actually inserting a filter cup  10 . In this embodiment, the handle  114  may be moved downward to begin the cycle such that heated water is passed over the stationary or rotating blade  166  to clean the blade. Alternatively, a button on the control panel  118  may be depressed to initiate the cleaning cycle. 
         [0091]      FIGS. 62 and 63  illustrate the tray  112  and the collection pan  136 .  FIG. 64  illustrates the bottom view of the tray  112  and shows the openings  32  of the cup  10  as viewed through an opening  140  in the bottom of the tray  112  that permits brewed coffee to flow out. 
         [0092]      FIG. 25A  schematically illustrates how ground coffee  128 , which is ground from whole coffee beans  20  in a procedure described below, is infused with heated water to produce coffee. The ground coffee  128  is located in the cup  10  and heated water is introduced from above through a water outlet  132  as indicated by the arrow  142 . The heated water flows through the ground coffee  128  in the cup  10  and exits from the apertures  32  in the bottom of the cup  10  as shown by arrow  144 . 
         [0093]      FIGS. 26 and 27  illustrate certain internal components of the appliance  100 . As shown therein, the water reservoir  116  is filled with water. The tray  112  is withdrawn to permit placement of a cup  10  into a receiving bracket  124  in the tray  112 , as shown in  FIGS. 18 and 19 . The tray  112  is then pushed back into the appliance to the position shown in  FIG. 20 . The handle  113  is then moved downwardly, as shown in  FIGS. 21 and 22 . Such movement of the handle  114  causes the cup  10  to be raised upwardly for grinding of the coffee beans  20  in the cup  10 , as described below. The appliance  100  includes a heater  146  and pump  148  to heat water from the reservoir  116  and route it through a supply conduit to perform a brewing operation as described with reference to  FIG. 25A . As shown in  FIGS. 26-29 , a grinder motor  150  is positioned in the housing  110  of the appliance  100  to carry out grinding of the coffee beans  20  in a manner described below. A hot water tube  152  carries heated water from the heater  146  to the water outlet  132  located above the tray  112 . 
         [0094]    As best shown in  FIGS. 27 and 29 , lifting mechanism  156  is activated by the handle  114  in order to cause movement of the cup  10  between a lowered position and a raised position. The mechanism  156  includes a linkage arm  158 , a pin  160  operatively attached to the receiving bracket  124  of the tray  112  and associated slot  162 , and a plate  164  in which the slot  162  is located. In operation, upon moving the handle  114  in the downwards direction, pin  160  follows the path of the slot  162  and causes the cup  10  and the receiving bracket  124  to be lifted upwards into the grinding blade. Guideposts  161  are received in bore holes  163  of the receiving bracket to ensure proper orientation and alignment of the cup  10  with the grinding blade. Lowering of the cup  10  follows the reverse process. 
         [0095]    Referring to  FIG. 30 , the appliance  100  includes a grinding blade  166  attached to and driven by a rotary output shaft  168  associated with the grinder motor  150 . When the handle  112  is moved to the lower position as shown in  FIG. 28 , the cup  10  is raised so that the blade  166  engages and pierces through the foil cover  18  and enters the cup  10  and comes into contact with the coffee beans  20 . The cup loading/raising mechanism  156 , which is activated by the handle  114 , moves the cup  10  between this raised position for grinding, and a lowered position. The spring  154  is a user assist spring, which biases the tray  112  outwards from the housing  110  when then handle  114  is raised, in order to insert a cup  10 . 
         [0096]    As shown in  FIG. 31 , movement of the handle  114  to the raised position unlocks the tray  112  so it slides out under force of the spring  154  in cooperation with a plate  165  (which serves as a anchoring object for the spring to work off of) in order to allow placement of a cup  10  into the receiving bracket  124  of the tray  112 . A user then places a cup  10  into the tray  112  as shown in  FIG. 32 . The tray  112  must be manually pushed back into the closed position as shown in  FIG. 33  until it locks in place by the tray lock  170  shown in  FIG. 34 . 
         [0097]      FIGS. 35-37  illustrate the piercing and grinding sequence in accordance with the present invention. As shown in  FIG. 35 , the filter cup  10  is raised upwardly toward the blade  166 , in the direction of arrow F when the handle  114  is lowered.  FIG. 36  illustrates the position of the cup  10  when it is fully raised. In that position, a seal ring  172 , such as an O-ring, engages a top rim of the cup  10  so that when the brewing process occurs the cup  10  may be pressurized.  FIG. 37  illustrates the lowered position of the cup  10  after grinding and brewing occur and the handle  114  is raised. Importantly, the seal ring  172  seals the top of the cup  10  so that the cup may be pressurized. In the preferred embodiment, the cup is pressurized in excess of 200 kilopascals (2 bars) during brewing, although other pressures may be employed without departing from the broader aspects of the present invention. 
         [0098]    Various views of the grinding blade  166  for grinding the whole coffee beans are shown in  FIGS. 38-43 . As shown therein, the blade  166  has a V-shaped configuration. Importantly, the blade  166  has insert cutting edges  174  so that the foil cover  18  of the cup  10  can be pierced when the cup  10  is raised upon downwards movement of the handle  114 . The top of the blade also includes upward facing extract cutting edges  176  for cutting through the foil cover  18  when the cup  10  is lowered away from the blade subsequent to brewing, upon upwards movement of the handle  114 . Each leg of the “V” is also formed with an opposed recess  178  and raised ridge  180  to facilitate grinding of the coffee beans  20 , as described hereinafter. The blade  166  also includes a collar  182  for connection to the output shaft  168  of the grinding motor  150 . In such an embodiment, the blade  166  may be removable for replacement and/or more thorough cleaning. In an alternative embodiment, the blade  166  is integrally formed or otherwise fixedly secured to the output shaft  168  of the motor  150 . As will be readily appreciated, the slim profile of the blade  166  puts cuts a slot a minimal width in the foil cover  18  to prevent coffee grounds  128  from being thrown out of the cup  10  during grinding. In addition, the shape and configuration of the blade  166  facilitates cleaning. 
         [0099]      FIG. 44  illustrates the cup  10  being raised toward the blade  166  and  FIG. 45  illustrates the blade  166 , by way of the insert cutting edges  174 , piercing the foil cover  18  of the cup  10 . In both  FIGS. 44 and 45  the coffee beans  20  in the cup  10  are not yet ground. After grinding, the beans  20  have been transformed into ground coffee  128 . Brewing occurs, as described above, and the cup  10  is then lowered as shown in  FIGS. 46 and 47  such that the extract cutting edges  176  of the blade  166  again pierce the foil cover  18 , if necessary, to facilitate removal of the cup  10  from the blade  166 . 
         [0100]    Referring now to  FIGS. 48-50 , the actual grinding process is illustrated. Upon actuation of the grinding motor  150 , the grinding blade  166  rotates at a high frequency sufficient to grind the coffee beans  20  in the filter cup  20  to transform the coffee beans  20  from whole beans, as shown in  FIG. 48 , to grinds, as shown in  FIG. 60 . In particular, the blade  166  is rotated in a direction (see  FIG. 49 ) that causes the ridge  180  on the blade  166  to strike/impact the coffee beans  20  to cause them to split. Over time, numerous impacts from the blade itself, and most importantly, by the ridges  180 , gradually reduce the size of the coffee beans to fine grounds sufficient for brewing. In an embodiment, the blade  166  may continue to rotate at a predetermined frequency during the brewing process, i.e., during the time during which hot water is passed through the cup  12 . The frequency of rotation during brewing may be the same as, or different from, the frequency utilized to grind the coffee beans  20 . In other embodiments, the blade  166  may be utilized to stir drink ingredients during brewing, such as to facilitate dissolution of drink ingredients into the water passing through the cup  10  (e.g., when utilizing iced tea drink ingredients in place of whole coffee beans). As will be readily appreciated, stirring the drink ingredients/coffee beans within the cup  10  while brewing may produce a better tasting beverage. In particular, stirring during brewing may improve the contact between the coffee grounds  128  and the hot water, which may improve coffee quality and/or concentration. 
         [0101]    In an alternative embodiment, the filter cup  10  may be retracted from the grinding blade  166  prior to distributing heated water to the cup  10 . As will be readily appreciated, this ensures that the grinding blade  166  only touches the coffee when it is dry (i.e., when it grinds the coffee beans  20  prior to brewing). Accordingly, grounds coffee is not as susceptible to sticking to the blade  166  as it would be if the blade  166  and ground coffee  128  were present together in a wet environment and, as such, keeps the blade substantially free of coffee grounds without having to clean the blade. 
         [0102]      FIGS. 52-57  illustrate an alternative configuration for a grinding blade  184  that may be utilized with the appliance  100 . As shown therein, the blade has a V-shaped configuration and has a piercing edge  186  for piercing the foil cover  18  of the cup  10 . The blade  184  also has two horizontally extending flanges  188 ,  190  to facilitate grinding of the coffee beans  20  and two upward edges  192 ,  194  for again cutting through the foil  18  when the cup  10  is lowered away from the blade  184 . As with the blade  166  of the preferred embodiment, the blade  184  may be releasably attached to the output shaft  168  of the grinding motor  150 , or it may be integrally formed or otherwise permanently affixed thereto. 
         [0103]    The path of water used in the process of the present invention is illustrated in  FIG. 58 . First, the reservoir  116  is filled with water. In an embodiment, the reservoir  116  may be releasably received on the housing  110  such that a user can remove the reservoir  116  to fill it with water and then place it on the housing  110 . As will be readily appreciated, such a configuration may be easier than bring a water source to the reservoir itself. The reservoir  116  may have a removable lid  194  as shown in  FIG. 60  to facilitate filling with water. A water outlet  196 , best shown in  FIGS. 17-24 , permits water to flow from the reservoir  116  under the force of gravity. The outlet  196  may be equipped with a valve  198  of a type commonly known to those skilled in the art, wherein the valve my be electronically activated and controlled by means of a conventional controller from an open position to a closed position, and vice versa. During brewing, water exits the reservoir  116  through the outlet  196  and travels through a first tube  200  until it reaches the pump  148 . The pump  148  pumps the water through the heater  146  in order to heat the water to a desired, predetermined temperature. The water passes from the heater  146  through the hot water supply tube  152  to the water outlet  132 . 
         [0104]    In an embodiment, at the end of the brewing process, the flow of water will be shut off prior than the heater such that steam will be generated to push or blow out excess liquid remaining in the cup  10 . As will be readily appreciated, this steam blast ensures that the last few drops of coffee do not remain in the cup  10  and prevents dripping. 
         [0105]    As shown in  FIG. 25B , in an embodiment, the water outlet  132  is a shower head in the form of an annular tube or ring  208  having a plurality of apertures  210  formed therein for distributing heated water. Heated water emitted from the apertures  210  of the shower head  132  is used both for brewing coffee and for rinsing the blade  166  in the cleaning operation. During brewing the heated water leaving the water outlet/shower head  132  enters the cup  10  which, at this point in the process, contains ground coffee  128 . The water, now brewed coffee, exits the cup  10  through the apertures  32  in the floor  26  of the cup  10 . As it exits the cup through the apertures  32 , it travels down through an exit conduit in the tray  112  before emitting through the tray exit  202 . In an embodiment, the tray may include a flow softening member  204  directly below the apertures  32  of the filter cup  10 . The flow softening member retards the direct flow of brewed coffee into the coffee mug  109  so that the brewed coffee doesn&#39;t gush out and splash a user or create a mess. After leaving the exit  202 , the water, which has now become brewed coffee, falls into the coffee mug  109 . The volume of liquid selected, corresponding to the serving size, is pre-selected using the controls  118 , and the pump  148  and water outlet  196  are accordingly controlled to permit flow of only the selected amount before shutting off flow. 
         [0106]      FIGS. 65-67  illustrate an alternative configuration of the drip tray  106  in accordance with another embodiment of the present invention. As shown therein, the drip tray is moveable between a first position, as shown in  FIG. 66 , in which the tray  106  is positioned below the brewed coffee exit  202 , and a second position, as shown in  FIG. 7 , in which the drip tray  106  is housed within the base  102  of the appliance  100 . With the drip tray  106  in the position shown in  FIG. 67 , taller cups/mugs  206  may be accommodated. 
         [0107]      FIG. 68  illustrates a coffee appliance  300  having an alternative configuration in accordance with one embodiment of the present invention. As shown therein, instead of the cup  10  being installed vertically and the grinding blade  166 , brew shower head  132  and motor  150  being in a vertical position above the cup  10 , these elements are oriented horizontally. In particular, as shown therein, the filter cup  10  is installed in a horizontal orientation within the housing  110 . In addition, the grinding motor  150 , shower head  132  and blade  166  are positioned to the side of the cup  10  in a horizontal position. In this embodiment, the appliance  300  includes a conduit  302  in communication with the bottom of the cup  10  such that brewed coffee exits the cup and is routed through the conduit  302  to the outlet  202  for distribution into a user&#39;s cup  109 . 
         [0108]      FIGS. 69 and 70  illustrate a coffee appliance  400  according to yet another embodiment of the present invention. The coffee appliance  400  is similar in configuration to that of the appliance  100  disclosed above, with a few notable differences. As shown therein, instead of the motor  150 , blade  166  and shower head  132  being stationary and the cup  10  being lifted into engagement with the blade  166 , in this embodiment, the brew shower head  132 , motor  150  and blade  166  are configured to move towards and away from a stationary cup  10 .  FIG. 69  illustrates a first position of the motor  150 , blade  166  and brew head  132  above the stationary filter cup  10 . The motor  150 , blade  166  and brew head  132  are moveable in the vertical direction to a second position, shown in  FIG. 70 , in which the blade is disposed within the cup  10 . The vertical movement of the motor  150 , blade  166  and shower head  132  may be effectuated by utilizing mechanical action or electrical actuators. The coffee appliance  400  according to this embodiment may be characterized as having an active brew assembly (motor  150 , grinding blade  166  and shower head  132 ) and a passive filter cup  10 , as opposed to an active filter cup  10  and passive brew assembly. 
         [0109]    While the preferred embodiment contemplates the grinding and brewing of coffee from whole coffee beans, the present invention is not intended to be limited in this regard. In particular, it is contemplated that the present invention apparatus and method are not limited to cups containing whole bean coffee, per se, and the invention may be used with cups containing ground coffee, partially ground coffee, tea leaves, ground tea, or drink mix ingredients. In addition, the appliance according to the embodiments of the present invention can make/brew beverages from any ingredients contained within the filter cup, and is not limited to brewing coffee from whole coffee beans. 
         [0110]    Although this invention has been shown and described with respect to the detailed embodiments thereof, it will be understood by those of skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed in the above detailed description, but that the invention will include all embodiments falling within the scope of this disclosure.

Technology Classification (CPC): 0