Beverage cartridge and filter assembly

• US 20030222089A1
• Filed: 03/07/2003
• Published: 12/04/2003
• Est. Priority Date: 03/14/2002
• Status: Active Grant

• Current Assignee: 1693778 Ontario Limited
• Original Assignee: Robert Hale
• Inventors: Hale, Robert
• Granted Patent: US 6,810,788 B2
• Time in Patent Office: Days
• US Class Current: 220/574
• CPC Class Codes: B65D 85/8061 Filters

Abstract

A beverage cartridge comprises a container having a sidewall extending from a first surface and a lip provided at an open end of the container. A cover is coupled to the lip of the container to cover the open end and seal the container. A sloped step is formed in the sidewall and a laminated filter structure is coupled to the sloped step. The laminated filter structure subdivides the container to form a brewing chamber and a beverage receiving chamber. The laminated filter structure includes first and second filter elements, both having edge portions. A seal is provided between the edge portions of the first and the second filter elements. The second filter element has a higher wet strength than the first filter element and the second filter element is located downstream of the first filter element. A beverage powder is contained in the brewing chamber. The container is pierceable to allow injection of liquid into the brewing chamber and to allow prepared beverage to be extracted from the container.

Claims

1. A beverage cartridge comprising:

a container having a sidewall extending from a first surface and a lip provided at an open end of the container;

a cover coupled to the lip of the container to cover the open end and seal the container;

a step formed in the sidewall;

a laminated filter structure coupled to the step, the laminated filter structure subdividing the container to form a brewing chamber and a beverage receiving chamber, the laminated filter structure having a first filter element with a first edge portion, the first filter element being comprised of a first material, a second filter element with a second edge portion, the second filter element being comprised of a second material, the second material differing from the first material, and a seal provided between the first edge portion and the second edge portion, the second filter element having a higher wet strength than the first filter element and the second filter element being located downstream of the first filter element; and

a beverage powder contained in the brewing chamber,

wherein the container is pierceable to allow injection of liquid into the brewing chamber and to allow prepared beverage to be extracted from the container.

2. The beverage cartridge according to claim 1, wherein said first filter element is comprised of cellulose fibres.

3. The beverage cartridge according to claim 1, wherein said first filter element is comprised of a blend of cellulose and polymer fibres.

4. The beverage cartridge according to claim 1, wherein said second filter element is comprised of a polymer.

5. The beverage cartridge according to claim 1, wherein said second filter is comprised of polypropylene.

6. The beverage cartridge according to claim 1, wherein said second filter element is one of polyester and polystyrene.

7. The beverage cartridge according to claim 1, wherein said laminated filter structure further includes a third filter element comprised of a third material, fixed to one of said second and said first filter elements, at an edge portion thereof.

8. The beverage cartridge according to claim 7, wherein said third filter element is comprised of polyester.

9. The beverage cartridge according to claim 7, wherein said third filter element is comprised of polyester threads fixed to said second filter element.

10. The beverage cartridge according to claim 1, further comprising a support, offset from the first surface for supporting a portion of the laminated filter structure during brewing.

11. The beverage cartridge according to claim 10, wherein the support comprises a generally conical recess having an offset wall spaced from the first surface.

12. The beverage cartridge according to claim 1, wherein elasticity of the second filter element permits expansion of the second filter element under pressure while providing support for the first filter element.

13. The beverage cartridge according to claim 1, wherein the step is sloped.

14. The beverage cartridge according to claim 1, wherein said laminated filter structure is heat sealed to the sloped step.

15. The beverage cartridge according to claim 1, further comprising a shoulder formed in the sidewall in the brewing chamber, for facilitating distribution of the liquid in the brewing chamber.

16. The beverage cartridge according to claim 1, wherein the second filter element is comprised of polypropylene extruded material.

17. The beverage cartridge according to claim 1, wherein the second filter element is comprised of polypropylene extruded strands welded together.

32. A process for fabricating the beverage cartridge of claim 1, comprising:

forming the container;

coupling the filter to the step of the container by applying a heating device to an exterior of said container, at said step;

depositing said beverage powder in said brewing chamber of said container; and

heat sealing said cover to said lip of said container.

33. The process for fabricating the beverage cartridge according to claim 32, wherein forming the container includes stamping said container from an aluminum sheet having a polypropylene file on one side thereof.

34. The process for fabricating the beverage cartridge according to claim 33, wherein said stamping is a one-step stamping process.

35. The process for fabricating the beverage cartridge according to claim 33, further comprising:

stamping said first and said second filter elements; and

welding said first and second filter elements together at outer edges thereof,

prior to the step of coupling the filter to the step of the container.

18. A laminated filter structure for subdividing a beverage cartridge to form a brewing chamber, said laminated filter structure comprising:

a first filter element having a first outer edge portion, the first filter element being comprised of a first material;

a second filter element having a second outer edge portion, the second filter element being comprised of a second material, the second material differing from the first material;

a seal provided between said first outer edge portion and said second outer edge portion; and

wherein said second filter element has a higher wet strength than said first filter element and said second filter element is located downstream of said first filter element.

19. The filter according to claim 18, wherein said first filter element is comprised of cellulose fibres.

20. The laminated filter structure according to claim 18, wherein said first filter element is comprised of a blend of cellulose and polymer fibres.

21. The laminated filter structure according to claim 18, wherein said second filter element is comprised of a polymer material selected from the group consisting of polyester, polypropylene and polystyrene.

22. The laminated filter structure according to claim 18, wherein the second filter element is comprised of polypropylene extruded material.

23. The laminated filter structure according to claim 18, wherein the second filter element is comprised of polypropylene extruded strands welded together.

24. The laminated filter structure according to claim 18, further comprising a third filter element comprising a third material fixed to one of said first and said second filter elements.

25. The laminated filter structure according to claim 24, wherein said third filter element is comprised of polyester.

26. The laminated filter structure according to claim 24, wherein said third filter element is comprised of polyester threads fixed to said second filter element.

27. A beverage cartridge comprising:

a container having a sidewall extending from a first surface and a lip provided at an open end of the container;

a cover coupled to the lip of the container to cover the open end and seal the container;

a sloped step formed in the sidewall;

a filter coupled to the sloped step, the filter subdividing the container to form a brewing chamber and a beverage receiving chamber; and

a beverage powder contained in the brewing chamber,

wherein said container is pierceable to allow injection of liquid into the brewing chamber and to allow prepared beverage to be extracted from the container.

28. The beverage cartridge according to claim 27, further comprising a support, offset from the first surface for supporting a portion of the filter during brewing.

29. The beverage cartridge according to claim 28, wherein the support comprises a generally conical recess having an offset wall spaced from the first surface.

30. The beverage cartridge according to claim 27, wherein elasticity of the second filter element permits expansion of the second filter element under pressure while providing support for the first filter element.

31. The beverage cartridge according to claim 27, wherein the cover includes at least one tab for orienting the beverage cartridge in a preferred orientation.