U.S. patent application number 13/584079 was filed with the patent office on 2013-02-21 for disposable biodegradable beverage package.
This patent application is currently assigned to Data Machine International. The applicant listed for this patent is George Gorbatenko. Invention is credited to George Gorbatenko.
Application Number | 20130045308 13/584079 |
Document ID | / |
Family ID | 47712833 |
Filed Date | 2013-02-21 |
United States Patent
Application |
20130045308 |
Kind Code |
A1 |
Gorbatenko; George |
February 21, 2013 |
DISPOSABLE BIODEGRADABLE BEVERAGE PACKAGE
Abstract
A biodegradable pod or package designed to work in single serve
beverage machines. The package of the present invention includes a
base, a filter, and a top, all of which are biodegradable. In some
embodiments, the base and filter are formed from a biodegradable
polymeric material such as polylactic acid (PLA); preferably, both
the base and the filter are formed from PLA or include a coating of
PLA thereon (for example, paper with a PLA coating). The top can be
formed from a cellulosic material or other plant-based material.
The package utilizes a unique bond between the three components so
as to withstand the temperature and pressures to which the pod is
exposed by the beverage machine. The bond is formed by melted or
softened biodegradable polymeric material from the base and the
filter that also adheres the top.
Inventors: |
Gorbatenko; George; (St.
Paul, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gorbatenko; George |
St. Paul |
MN |
US |
|
|
Assignee: |
Data Machine International
St. Paul
MN
|
Family ID: |
47712833 |
Appl. No.: |
13/584079 |
Filed: |
August 13, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61575326 |
Aug 17, 2011 |
|
|
|
Current U.S.
Class: |
426/84 ;
426/394 |
Current CPC
Class: |
Y02W 90/10 20150501;
B65D 85/8043 20130101; Y02W 90/13 20150501; Y02W 90/12
20150501 |
Class at
Publication: |
426/84 ;
426/394 |
International
Class: |
B65D 85/804 20060101
B65D085/804; B65B 51/02 20060101 B65B051/02 |
Claims
1. A single use beverage package comprising: a base comprising
biodegradable polylactic acid-containing material; a top comprising
biodegradable cellulose-based material, together the base and the
top defining an interior volume; a filter comprising biodegradable
polylactic acid-containing material positioned in the interior
volume, the filter retaining beverage ingredients; and wherein the
filter and top are hermetically sealed to the base via the
polylactic acid in the base and filter.
2. The beverage package of claim 1 wherein the polylactic
acid-containing material in the base comprises a polylactic acid
film or sheet.
3. The beverage package of claim 1 wherein the polylactic
acid-containing material in the base comprises water impermeable
paper coated with polylactic acid.
4. The beverage package of claim 1 wherein the polylactic
acid-containing material in the filter comprises water permeable
paper at least partially coated with polylactic acid.
5. The beverage package of claim 1 wherein the base comprises a
multilayer film or sheet containing polylactic acid and at least
one low permeable polymer.
6. The beverage package of claim 1 wherein the filter comprises a
nonwoven material comprising polylactic acid and paper fibers.
7. The beverage package of claim 1 wherein the top comprises a
clear cellulosic layer, a graphics layer, and a foil layer.
8. The beverage package of claim 1 wherein the base further
comprises an egg-based coating, a corn-based coating, a soy-based
coating, a paraffin coating, or a beeswax coating.
9. The beverage package of claim 1 wherein the base is a cup having
side walls, a rim, and a peripheral flange around the cup's
rim.
10. The beverage package of claim 9 wherein the top is hermetically
sealed to the base and filter at the peripheral flange around the
cup's rim.
11. The beverage package of claim 9 wherein the sidewalls of the
cup are pleated.
12. The beverage package of claim 11 wherein the pleats provide
substantially three overlapping layers of the polylactic
acid-containing material of the base when the pleats are
compressed.
13. The beverage package of claim 1 further comprising a pressure
relief valve.
14. A single use beverage package comprising: a pouch having side
walls and an interior volume comprising biodegradable polylactic
acid-containing material; a filter comprising biodegradable
polylactic acid-containing material positioned in the interior
volume of the pouch, the filter retaining beverage ingredients; and
wherein the filter is sealed to the sidewalls of the pouch via the
polylactic acid in the base and filter.
15. A method of making a single use beverage package, comprising:
providing a base comprising biodegradable polylactic
acid-containing material; providing a filter comprising
biodegradable polylactic acid-containing material; providing a top
comprising biodegradable cellulose-based material; and attaching
the filter and top to the base with the polylactic acid in the base
and filter to form a seal between the base, filter and top by
applying heat and/or pressure to the base and the top.
16. The method of claim 15 wherein the base is a cup having side
walls, an opening, and a peripheral flange around the cup's
rim.
17. The method of claim 15 wherein the top is hermetically sealed
to the base and filter at the peripheral flange around the cup's
rim.
18. The method of claim 17 wherein the sidewalls of the cup are
pleated.
19. The method of claim 18 wherein the pleats provide substantially
three overlapping layers of the polylactic acid-containing material
of the base when the pleats are compressed to form the seal between
the base, filter and top.
20. The method of claim 15 further comprising attaching the filter
and top to the base with a sealing agent.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional
application 61/575,326 filed Aug. 17, 2011 titled "Biodegradable
Beverage Pod and Method of Making Same", the entire disclosure of
which is incorporated by reference herein.
BACKGROUND
[0002] The present disclosure is directed to disposable, single use
and single serving beverage packages.
[0003] Coffee machines for offices, homes, and other establishments
provide single serve cups of coffee. Typically, users can select
from a large variety of coffee types, insert a sealed packet or pod
containing the desired beverage choice, and within a minute or two
enjoy a freshly brewed cup of coffee or other beverage. After use,
the spent pod is thrown away.
[0004] Single serve packets come in a variety of sizes and shapes
and can be referred to as pods, cups, K-Cups, packets, T-pouches,
etc., depending on which coffee machine the packet was designed to
fit. Typically, the package, pod or packet is made of plastic
and/or aluminum foil. In order to make a good cup of coffee or
other beverage, the packets have a defined interior volume that
holds the ingredients, such as ground coffee, tea, or other
ingredients. Depending on the nature of the contents, it may
contain a filter in which case the volume will be divided in two
parts: that which is above (i.e., upstream) and that which is below
(i.e., downstream) of the filter.
[0005] The package is hermetically sealed to preserve the product's
freshness. In operation, this seal is broken by a piercing means
typically located on the brewing machine, allowing hot water and/or
steam to enter the packet and intermix with the contents. A second
opening in the package, which may be pierced or cut by the machine,
allows the brewed product to exit the package and flow to a
receiving cup. After the beverage has been brewed, the spent
package is discarded.
[0006] Structurally, the package can be broken down to three
elements: a top or sealing means; a filter to retain the spent
product (if of a granular form such as coffee); and a base or
volume defining means. Depending on the particular machine being
used, the package will take on different shapes. All however, will
typically contain the structural elements described above, namely,
a top, filter, and a base.
[0007] Shown in FIG. 1 is a package commonly known as the
K-Cup.RTM. package designed for use with a Keurig coffee machine.
Hot water and/or steam enters through the pierced top 1 by means of
a piercing means 6, driven through the material contained by the
filter 2, and exits the pierced base 3 via a hole formed by second
piercing means 5.
[0008] Another common package is shown in FIG. 2; the "T-Disc" is a
pod designed for a Tassimo brewing system. Aside from special
features, the basic elements parallel those of the K-Cup.RTM.
package. A piecing means 6b provides access through a top 1b
allowing water/steam to flow through coffee contained by filter 2b
and exiting the base cup 3b by means of a hole formed by a second
piercing means 5b.
[0009] FIGS. 3A and 3B show the "Flavia Fusion" single serve
package designed for use with a Flavia brewer. The plastic cover 1c
is pierced by means 6c allowing passage of hot water and or steam
into the volume defined by side walls 3c. The brewed liquid escapes
the volume through a slit 5c. Solid contents are retained in the
volume by filter 2c attached to side walls 3c.
[0010] As can be seen, all the prior art packages or pods are
structurally similar. All have a top that is pierced to allow the
entry of hot water and/or steam. All use a filter affixed to the
volume to retain the spent ingredients (e.g., coffee grounds). All
have a means for the brewed liquid to exit the space beneath the
filter.
SUMMARY
[0011] This disclosure describes a biodegradable pod or package
designed to work in single serve beverage machines. The package of
the present invention includes the three main components: a base, a
filter, and a top. However, the package of the present invention
utilizes a unique bond between the three components so as to
withstand the temperature and pressures to which the pod is exposed
by the beverage machine. In some embodiments, the bond is formed by
melted or softened biodegradable polymeric material from the base
and the filter that also adheres the top. In addition, friction
force between the filter and the inside walls of the base offloads
some of the force placed on the bond, further increasing the
integrity of the pod. In some embodiments, the base and filter are
formed from a material that includes biodegradable polymeric
material, such as polylactic acid (PLA). The biodegradable
polymeric material may be a sheet or film, may be a coating on a
carrier material, or may be fibers forming a woven or nonwoven
sheet. For example, the base and/or filter can be formed from
suitable water impermeable or water permeable paper which is then
treated (e.g., coated) with PLA. The top is also formed from
biodegradable material. In some embodiments, the top is formed from
a cellulosic material or other plant-based material and a suitable
biodegradable sealing agent may be used to seal the top to the
base.
[0012] A first particular embodiment of the invention is a single
use beverage package comprising a base comprising biodegradable
polylactic acid-containing material; a top comprising biodegradable
cellulose-based material, together the base and the top defining an
interior volume; a filter comprising biodegradable polylactic
acid-containing material positioned in the interior volume, the
filter retaining beverage ingredients; and wherein the filter and
top are hermetically sealed to the base via the polylactic acid in
the base and filter.
[0013] A second particular embodiment of the invention is a single
use beverage package comprising a pouch having side walls and an
interior volume comprising biodegradable polylactic acid-containing
material; a filter comprising biodegradable polylactic
acid-containing material positioned in the interior volume of the
pouch, the filter retaining beverage ingredients; and wherein the
filter is sealed to the sidewalls of the pouch via the polylactic
acid in the base and filter.
[0014] A third particular embodiment of the invention is a method
of making a single use beverage package comprising providing a base
comprising biodegradable polylactic acid-containing material;
providing a filter comprising biodegradable polylactic
acid-containing material; providing a top comprising biodegradable
cellulose-based material; and attaching the filter and top to the
base with the polylactic acid in the base and filter to form a seal
between the base, filter and top by applying heat and/or pressure
to the base and the top.
[0015] These and various other features and advantages will be
apparent from a reading of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWING
[0016] The invention may be more completely understood in
consideration of the following detailed description of various
embodiments of the invention in connection with the accompanying
drawing, in which:
[0017] FIG. 1 is a schematic cross-sectional view of one embodiment
of a single use package, also referred to as a filter cup.
[0018] FIG. 2 is a schematic cross-sectional view of a second
embodiment of a single use package, also referred to as a pod.
[0019] FIG. 3A is a schematic front view of a third embodiment of a
single use package; FIG. 3B is a cross-sectional side view of the
package in cross section.
[0020] FIG. 4 is a cross sectional view of a preferred embodiment
of a package of the present invention.
[0021] FIGS. 5A-5C are enlarged views of a portion of the
embodiment of FIG. 4 showing a step-wise procedure for sealing the
preferred package.
[0022] FIG. 6A is an enlarged, schematic side view of a portion of
the package of FIG. 4 showing an out-gassing valve in a closed
position; FIG. 6B illustrates the out-gassing valve in open
position;
[0023] FIG. 6C is a top plan view of the package portion showing
the out-gassing valve.
[0024] FIG. 7 is a schematic perspective view of a preferred
embodiment of a single use package of the present invention.
[0025] FIG. 8 is a top plan view of the material used to form the
package of FIG. 7.
[0026] FIG. 9 is a side plan view of a preferred embodiment of a
single use package of the present invention.
[0027] FIG. 10 shows three different possible pleat configurations
suitable for a single use package of the present invention.
[0028] FIG. 11 illustrates a top view of an embodiment of a pouch
for use in a single use package of the present invention; section
BB' is a cross-sectional side view of the pouch taken along line
B-B' of FIG. 11.
[0029] FIG. 12 is a schematic cross-sectional side view of a
package of the invention incorporating the pouch of FIG. 11.
[0030] FIG. 13 is a schematic cross-sectional side view of an
alternate embodiment of a single use package of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present disclosure provides biodegradable pods or
packages for single service beverage machines, such as coffee
machines. Examples of such machines include those available from
Keurig, Tassimo (by Bosch), and Flavia Fusion (by Mars). The
packages of the present invention can be used with existing single
serve coffee machines, may be hermetically sealed, they are
economical to produce, and biodegradable after use. Prior to use,
the package is sealed to preserve the freshness of the product
present within the package. During use in a single serve brewing
machine, the package is ruptured (e.g., a seal is broken) and hot
water and/or steam is allowed to pass through the filter, through
the beverage ingredients, out from the package and then into the
cup, providing a beverage to be enjoyed. Although the following
discussion uses the term "package", it is understood that use of
this term is not limiting and is intended to encompass products
that may alternately be called pods, cups, packets, and the
like.
[0032] In the following description, reference is made to the
accompanying drawing that forms a part hereof and in which are
shown by way of illustration at least one specific embodiment. The
following description provides additional specific embodiments. It
is to be understood that other embodiments are contemplated and may
be made without departing from the scope or spirit of the present
invention. The following detailed description, therefore, is not to
be taken in a limiting sense. While the present invention is not so
limited, an appreciation of various aspects of the invention will
be gained through a discussion of the example provided below.
[0033] Unless otherwise indicated, all numbers expressing feature
sizes, amounts, and physical properties are to be understood as
being modified by the term "about." Accordingly, unless indicated
to the contrary, the numerical parameters set forth are
approximations that can vary depending upon the desired properties
sought to be obtained by those skilled in the art utilizing the
teachings disclosed herein.
[0034] As used herein, the singular forms "a", "an", and "the"
encompass embodiments having plural referents, unless the content
clearly dictates otherwise. As used in this specification and the
appended claims, the term "or" is generally employed in its sense
including "and/or" unless the content clearly dictates
otherwise.
[0035] The package of the present invention includes a base,
filter, and a top cover. In accordance with the invention, the base
is made from a polymeric biodegradable material or suitable
material (e.g., paper or other cellulosic or biodegradable
material) treated with polymeric biodegradable material. The filter
is present within the interior volume of the base and retains the
coffee or other beverage ingredients. The filter is made from a
polymeric biodegradable material, a PLA-paper fiber mix or
cellulose material (e.g., typical coffee filter material) that has
been optionally coated with PLA or other sealant material at least
in the seal area (i.e., the area where the seal with the cup and/or
top will be made). By using biodegradable polymeric material to
form the base and the filter, additional sealing materials to
assemble the package are avoided. In alternative embodiments where
a sealant material is used, suitable sealing agents or materials
include polymeric and biodegradable adhesives and resins. For
example, DuPont Surlyn.RTM. packaging adhesives and resins
available from DuPont, Wilmington, Del. are suitable sealing agents
for use in the present invention.
[0036] It is to be understood that although the following
discussion is directed to a single serving coffee package, the
package could be used for other single servicing beverages, such as
tea, hot chocolate, lanes, etc. Further, use of the term "single
serving" or variations thereof is intended to cover volumes of 4 to
12 fluid ounces (e.g., 4 oz, 6 oz, 8 oz, 10 oz, or 12 oz).
[0037] Referring again to the prior art package products, the
various package configurations are known. For example, as seen in
FIG. 1, a K-Cup.RTM. package has a top cover 1, the filter 2, and
base cup 3. In addition in FIG. 1, the piercing means 5, 6 from the
brewing machine for both the top and base are shown. The T-Disc, a
pod designed for the Tassimo Brewing System (shown in FIG. 2), is
functionally equivalent in a basic sense to the Kuerig cup, except
that the pod has a different aspect ratio (i.e., it is shorter and
wider). The Flavia Fusion package is shown in FIGS. 3A and 3B. Note
that the filter 2c is attached to the side walls 3c and that the
bottom of the package is slit, allowing brewed product to exit the
package. The packages of the present invention have several
features that differ from those of the prior art.
[0038] Referring to FIG. 4, a single use package having a base 9, a
filter 7 within base 9, and a top 8 is shown. Coffee or other
beverage ingredient is held between filter 7 and top 8. During use,
piercing means such as piercing means 5 would provide access for
hot water/steam to and from the ingredients in the package.
[0039] In accordance with this invention, base 9 is formed from a
biodegradable film or sheet material, preferably plant-based.
Examples of suitable materials include degradable polyethylene,
biodegradable polyester amide, polylactic acid, starch-based
polymers, cellulose derivatives and polypeptides. Polylactic acid
(i.e., PLA), a biodegradable polymeric material made from corn and
available from Cargill Inc., Minneapolis, Minn., is preferred for
base 9. PLA is obtainable as a film or sheet material that can be
readily molded and formed (e.g., vacuum formed). Alternately PLA
can be obtained as a bulk material that can be applied (e.g.,
coated) on a carrier material, such as a paper sheet or web.
Multiple base units 9 can be ganged formed as in a matrix array, or
handled individually. Some versions of PLA film or sheet material
include polyvinylidone chloride (PvdC) or polyglycolic acid (PGA)
to improve the barrier properties and inherently have a high
barrier resistance to O.sub.2. Alternatively, other treatments can
be used such as egg-based coating, paraffin spray, corn- or
soy-based substances or beeswax to improve barrier resistance to
O.sub.2. Although base 9 is shown in FIG. 4 as having smooth side
walls, the inclusion of ribs, gussets, braces and other such
structures to base 9 is contemplated, as adding such structures to
the generally-vertical surface will strengthen the wall thus
allowing a lesser thickness of material to be used for the same
strength. Various additional and alternate features of base 9 are
described later, in reference to FIGS. 7 through 10.
[0040] Filter 7 is positioned within base 9 and retains the coffee
grounds, both before and after use of the package. Filter 7 allows
water (or other liquid) to pass through the coffee and then through
filter 7 while retaining the grounds. During brewing, filter 7 is
the element that is subjected to the maximum amount of force
against it.
[0041] In accordance with this invention, filter 7 is formed from a
biodegradable polymeric material, preferably plant-based.
Polylactic acid (i.e., PLA), a biodegradable material made from
corn, is preferred for filter 7. Alternately filter 7 may include a
coating of PLA on a suitable substrate, such as paper or
cellulose.
[0042] The physical configuration of the filter media for filter 7
is an important design features. An overly restrictive filter weave
would lengthen brew time, and possibly result in rupturing the
filter. If the weave to too loose, the water may pass too quickly
through the filter, limiting the extraction of the coffee flavor
from the grounds. It has been determined that a filter material
that provides a 30-32 second brew time is preferred for a single
serving size. A preferred non-woven PLA filter material for filter
7 is available from Yamanaka Industry Co., Ltd, Kyoto, Japan under
the designation "Soilon NW 080" (80 gsm).
[0043] As one example, filter 7 may be pre-formed by a vacuum draw
means. A thin layer of resilient material, such as neoprene,
facilitates the draw and serves to ease handling and packaging. As
with base 9, multiple filters 7 can be arranged as a matrix (to
match that of the base cups) or individually handled.
[0044] Filter 7 may be formed and then coffee provided to the
filter immediately prior to assembly of the final package.
Alternately, a pre-filled filter pouch may be formed and then
subsequently inserted into base 9. See, for example, FIG. 11, where
a three-dimensional filter pouch 17 is illustrated. Pouch 17 is
formed with a charge of coffee 20 sandwiched between opposing
filter layers 18a and 18b. The coffee 20 is held in place by a
circumferential seal 19, such as a thermo-formed bond. As seen in
FIG. 11, a plurality of pouches 17 may be formed and then
subsequently separated. Preferably, after separation, a surplus 21
of filter material extends beyond seal 19.
[0045] Returning to FIG. 4, the single use package also includes
top 8, whose function is to seal the package (preferably
hermetically) and optionally identify the contents of the package
and as well as provide other information. Top 8 may be any color or
have any design or indicia thereon.
[0046] In accordance with this invention top 8 is also formed from
a biodegradable material. Top 8 may be formed from PLA material, or
may be formed from other suitable materials. It has been found that
it is difficult to provide pure PLA with the colorful and
decorative features, thus top 8 may be formed from materials other
than PLA. One suitable material for top 8 is a three-layer
material, having a clear substrate, graphics, and a foil-backed
substrate. Biodegradable films made by Innovia Films Ltd, England,
NatureFlex.TM. NKR and NatureFlex.TM. NM are sandwiched with
graphics by the Revere Group (Seattle, Wash.) to produce a
biodegradable product made from a tree-based cellulose that has the
look and feel of contemporary package tops. This material provides
the physical properties and decorative qualities for top 8 desired
while being biodegradable.
[0047] The package of the present invention may include a one-way
venting valve in top 8, preferably centered in top 8. Because the
coffee packaged in the biodegradable packages of this invention
will preferably and typically be fairly fresh, a high level of
out-gassing may be experienced from the coffee. To decrease the
pressure within the packaged, a valve comprising a plurality of
ports in a multi-layer top 8 is provided. If the three-layer
material for top 8 is that from The Revere Group, an additional
sheet or layer is preferably added to the to the three-layer
material in a separate operation. FIGS. 6A-6C illustrate one
embodiment of a suitable valve. Alternatively, a commercially
available biodegradable valve could be used.
[0048] The illustrated valve is formed by a plurality of ports 13
in a first or outer layer, illustrated as an annulus surrounding a
central port 14 in a second or inner layer. In FIG. 6A, the valve
is shown sealed, preventing outside air to enter through ports 13.
In FIG. 6B, the seal is shown open allowing excess CO.sub.2 to
escape through the central port 14 and then through channels or
alleys between the layers to annulus ports 13. FIG. 6C is a top
view that shows the annulus of small exit ports 13 and the central
portion 14. Such a valve is sufficiently small that is would not
detract from the package's appearance.
[0049] During assembly, filter 7 is positioned within base 9 and a
charge of freshly roasted and ground coffee is placed on filter 7,
if not already present. Preferably, filter 7 snugly fits in base 9,
but stops short of the closed end of base 9 (approximately 1/2 to
3/4 of the distance between the open end of base 9 and the closed
end, e.g., 2/3 of the distance). Having filter 7 stop short of the
bottom of base 9 defines a "brewing volume", allows for any
stretching of filter 7 and accommodates the mechanism that pierces
and/or drains brewed coffee from the package (see, for example,
piercing means 5 of FIG. 1). FIGS. 5A through 5C illustrate
formation of the seal between base 9 and filter 7 and thus
formation of the package. It is noted that freshly roasted coffee
emits CO.sub.2. For this reason, if no pressure relief valve is
present in the resulting package, it is recommended to wait at
least 24 hours before packaging the coffee in the package. Failure
to accommodate the out-gassing, may cause the package to rupture.
To guard against this failure while packaging fresh coffee, a
one-way, pressure relieve valve is preferably included in the
package to allow CO.sub.2 to escape while preventing air from
entering.
[0050] Referring to FIG. 5A, base 9 has a flange, lip or tab at its
open end. Filter 7 is held proximate and preferably in contact with
the tab base 9. Top cover 8 is seated over filter 7, thus
sandwiching filter 7 between base 9 and top cover 8. In accordance
with this invention, each of filter 7, base 9 and top 8 are
biodegradable. Base 9 and filter 7 both comprise PLA material,
either formed completely from PLA or having at least some amount of
PLA therein, preferably as an outer coating. Top cover 8 may be PLA
or material(s) other than PLA.
[0051] After positioning of filter 7 between base 9 and top cover
8, a sealing mechanism, such as top platen 10a and corresponding
bottom platen 10b, seals the three components together and a forms
a peripheral seal. The seal between the components should be
continuous along the entire circumference or periphery of the top
of the resulting package. Although it is preferred that a
continuous seal is formed, multiple seals may be formed and
connected to form the final continuous seal.
[0052] FIG. 5A illustrates the three distinct components (base 9,
filter 7 and top 8) just prior to contact with the anvils or
platens 10a, 10b. In FIG. 5B, the platen pair is shown applying
heat and/or pressure to the components 9, 7, 8. The heat and/or
pressure at least softens and optionally melts the PLA. A
temperature of about 160-180.degree. F. is adequate to soften
and/or melt the PLA without degrading the PLA. Note that in FIG.
5B, at least a portion of filter 7 and of base 9 are melted
together and appear homogenous. The melted together material has a
solid or semi-solid consistency, but in some embodiments, a portion
of the material may be liquid or otherwise flowable. In FIG. 5B, a
puddle 11 of PLA is shown. This puddle 11 can be used as an
adhesive to affix top 8 to filter 7, such as for those embodiments
where top 8 does not include PLA (for example, if top 8 is
cellulose). If top 8 comprises PLA or other biodegradable polymeric
material, that material will typically also soften or melt,
providing additional adherence. FIG. 5C shows the finished bond
with platens 10a, 10b retracted. The filter and the base remain
homogenous with no discernible distinction at the seal area, and
the top is dimpled or indented.
[0053] After formation of the package (as shown in FIG. 4), the
package is hermetically sealed with the coffee grounds positioned
between filter 7 and top 8. During the brew cycle, which provides
hot water and/or steam to the interior of the package, the bond
between base 9 and filter 7 is subjected to high force by the
water/steam and the coffee. Preferably, the failure limit for any
point in the bond is no less than 35-65 N/5 cm, thus essentially
assuring that filter 7 itself will fail before the bond between
filter 7 and base 9.
[0054] If a pre-filled filter is used, such as coffee pouch 17 from
FIG. 11, prior to sealing the three components together, coffee
pouch 17 is held in base 9 by filter surplus 21. Pouch 17, base 9
and top 8 are bonded together as described above.
[0055] Alternatively, a pre-filled filter may be retained within
base 9 without being sealed thereto.
[0056] As seen in FIG. 13, pouch 17 can be inserted in base 9 and
held in place by a suitable restrictive means 22, allowing adequate
volume between filter and base 9 for the brewing to be
accomplished.
[0057] The foregoing description has focused on using a
biodegradable polymeric material for base 9 and filter 7. The
following discussion provides various embodiments and alternate
features that could be incorporated into base 9. For example, there
are instances where a manufacturing process would be better suited
to forming base 9 from a suitable planar material, rather than by
molding.
[0058] Turning to FIG. 7, a generic base is illustrated. The base
has a base radius "r", a side wall length "l", an upper or open end
radius "R", and a flange, lip or tab width "t". To form such a
shape from a film or sheet of planar stock, a circle of material
with a radius ".SIGMA." is needed, where:
.SIGMA.=r+l+t (1)
[0059] To accommodate through folding the difference between the
starting circumference and the ending circumference, .delta.,
where:
.delta.=2.pi.(.SIGMA.-R), (2)
[0060] and where the material is pleated in a cupcake-paper fashion
to provide pleats in the side wall of the resulting base. In order
to evenly divide this excess along the periphery flange or rim,
approximately every 10 degrees (or 36 fold), the pleat width,
.DELTA., can be defined by:
.DELTA.2.pi.(.SIGMA.-R)/36. (3)
[0061] Finally, because the pleat folds back on itself, the pleat
width is halved (0.5.DELTA.).
[0062] In FIG. 8, the pleated yet flat construction used to form
the construction of FIG. 7 is shown, with an individual pleat
identified as 15 and the overall double back fold identified as 16.
As can be seen in FIG. 8, adjacent pleats 15 do not touch. By
reducing the number of pleats 15, the pleat width increases and the
flange or lip on the rim of the base cup can assume a uniform
thickness of three times the thickness of the starting stock
material.
[0063] In FIG. 10 shows several alternate pleat styles. In FIG. 10
(a), the original pleat, as shown in FIG. 8, is illustrated. The
distance between adjacent pleats is shown as "x". In FIG. 10 (b),
the distance between adjacent pleats is shown as "y" and is very
short, as adjacent pleats are very close, almost touching. When
compressed, the combined thickness will be uniformly 3.times. the
width of the stock formed by three overlapping layers of the
material. This uniformity will allow for a better seal to the top
(i.e., top cover 8). In FIG. 10 (c), another pleat style with
adjacent pleats almost touching is shown, with the shortest
distance between adjacent pleats shown as "z". This pleat
configuration also achieves a uniform 3.times. thickness of the
stock material.
[0064] Returning to FIGS. 7 and 8, as an example, in order to form
a cup having a side length "l" of 1.70 inch, a flange, lip or tab
width "t" of 0.15 inch, a base radius "r" of 0.72 inch, a planar
circle of material having a radius .SIGMA. of 2.57 inches is
needed.
[0065] When this material is folded using 36 evenly spaced pleated
it provides the desired cup size with a pleat width of approx.
0.023 inch.
[0066] After the paper is preferentially creased and pleated as
designed, a die set having a male and female die is used to draw
the folded paper to the desired geometrical shape (see FIG. 7).
Typically, the material is either PLA, includes PLA therein, or is
coated with PLA (e.g., a spray). In some embodiments, the material
may be coated with a coating (such as an egg wash) to render the
surface impermeable.
[0067] The previous discussion has been directed to single serving,
single use beverage package having a configuration generally
similar to that of the Keurig K-Cup.RTM. package (shown in FIG. 1).
It should be understood that the inventive features of this
discussion, that of utilizing biodegradable polymeric material such
as PLA for at least some of the package components, can be applied
to other package configurations.
[0068] For example, a package similar to the Flavia Fusion package
shown in FIG. 3 could be made using the features of the present
invention. The nozzle 4 could be injection molded from PLA and
affixed to biodegradable material side wall 3c which is formed as
shown, thereby creating the requisite internal volume. Alternately,
the nozzle 4 could be affixed and sealed to side wall 3c that
includes PLA. As with the K-Cup.RTM. package, melted PLA from the
filter serves as the adhesive to bond the filter to the side walls
of the package. The result is a modified package or pouch that is
biodegradable.
[0069] Thus, embodiments of the DISPOSABLE BIODEGRADABLE BEVERAGE
PACKAGE are disclosed. The implementations described above and
other implementations are within the scope of the following claims.
One skilled in the art will appreciate that the present invention
can be practiced with embodiments other than those disclosed. The
disclosed embodiments are presented for purposes of illustration
and not limitation, and the present invention is limited only by
the claims that follow.
* * * * *