CN1997568A - Device for brewing and method for producing the same - Google Patents

Abstract

Apparatus for brewing a brew substance from a liquid comprising: a container (40) for storing a liquid, the container comprising at least one aperture (44) for dispensing the liquid therefrom; a sealed package of filter paper containing a brew substance; and a heat sensitive film layer (18, 20) encapsulating the sealed packet (10), the encapsulated packet being disposed within the container at a location covering the at least one aperture, the container being configured to sit on top of a drinking container to allow liquid to drain from the at least one aperture thereof into the drinking container. Furthermore, the method of manufacturing a brewing apparatus comprises the steps of: configuring the container to store liquid for brewing and to dispense the liquid through at least one opening therein; packaging the filter paper sealed package containing the brewing substance with a thermosensitive film layer; disposing a packaging bag within the container at a location covering the at least one opening; and configuring the container to sit on top of the drinking container to allow liquid to drain from the at least one aperture thereof into the drinking container.

Description

Device for brewing and method for manufacturing same

This utility application claims priority to the following U.S. provisional applications: 60/528,547 filed December 10, 2003 and 60/546,518 filed February 20, 2004, both entitled "Microwave Coffee Brewers," and 2004 US Utility Application 10/937,720, entitled "Apparatus for Brewing and Method for Making the Same," filed September 9, all of which are hereby incorporated by reference in their entirety.

Background technique

The present invention is directed generally to brewing apparatus, and more particularly to apparatus suitable for use in a microwave oven for brewing a brewing substance into a liquid, and methods of making such apparatus.

Disposable microwaveable coffee brewers suitable for one-cup serving have been described in the literature. In these brewers, water is added to a water reservoir and the brewer with water is placed on a consumer's cup or mug of any known type for receiving a hot beverage. The brewer and cup are then placed in the microwave, where a properly set microwave brew takes about 5 minutes or less. During the brewing operation, the water is heated to the desired temperature in the water reservoir, and the water is mixed with the coffee charge in the brew chamber below the water reservoir. Finally, the brewed coffee is dispensed by gravity from the brew chamber into the drinking vessel.

One such microwavable coffee brewer is disclosed in US Patent No. 5,243,164, issued September 7, 1993 to Erickson et al., entitled "Beverage Builder." In Erickson's brewer, the reservoir includes at least one opening in its bottom for dispensing brewed liquid into a drinking vessel. A filter paper is positioned over the at least one opening in the bottom of the reservoir and a charge of coffee grounds is positioned on the filter paper. A heat-responsive membrane barrier is positioned over the coffee grounds charge and affixed to the inside perimeter of the reservoir to prevent the liquid in the reservoir from mixing with the coffee grounds until the liquid reaches the proper temperature.

To brew coffee with an Erickson brewer, a reservoir is filled with the appropriate amount of water and placed over a drinking cup or mug. The reservoir and cups were then placed in the microwave oven set to start at the desired setting for heating. As the water temperature reaches the melting temperature of the barrier material, the barrier ruptures and exposes the water to the coffee grounds for brewing. The brewed coffee is released to the cup by gravity through the filter paper and at least one opening of the reservoir.

While Erickson Brewers mentions the use of nitrogen purged (ie, filled) retail bags to hold multiple storage components, individual brewers, specifically their individual coffee charges, are not individually sealed. Thus, as soon as the multipack is opened, the freshness of the coffee begins to decrease. Likewise, the Erickson brewer performs flow-through brewing immediately after the diaphragm is ruptured, thus prohibiting progressive wetting of the grind prior to introduction of the brewing liquid into the serving cup. This lack of progressive wetting may leave air pockets within the grind and paper, which in turn has the potential to affect the extraction process in and around these air pockets.

Additionally, Erickson brewers do not provide a layer of filter paper over the grind. A disadvantage of this design is that the buoyant grinds can rise up into the reservoir which in turn relieves the water resistance of the grinds remaining in the brew chamber and allows a higher flow rate which ultimately results in less extraction. Another disadvantage of this design is that the grind will trap and remain where the fluid discharge pressure is greatest (ie, as low as possible relative to the centroid of the reservoir). The buoyant abrasives floating on or near the liquid surface do not benefit from the discharge pressure in order to assist the extraction process. Furthermore, the presence of abrasives within the reservoir is aesthetically undesirable and a cleaning burden if the reservoir is reused.

Thus, the present invention overcomes the above-mentioned drawbacks of existing brewers by providing an improved brewing device and a method of manufacturing the same.

Contents of the invention

According to an aspect of the present invention, an apparatus for brewing a brewing substance with a liquid comprises: a container for storing the liquid, the container including at least one aperture for dispensing the liquid therefrom; a sealed filter paper bag containing the brewing substance; and packaging The thermally sensitive film layer of the sealing pack, the packaging pack is disposed within the container in a position covering the at least one opening, the container being configured to sit on top of the drinking container to allow liquid to drain from the at least one opening into the drinking container.

According to another aspect of the present invention, a method of manufacturing a brewing device comprises the steps of: configuring a container to store liquid for brewing and dispensing the liquid through at least one opening therein; encapsulating the filter paper containing the brewing substance with a heat sensitive film layer and sealing a package; disposing the packaging package within the container at a position covering the at least one opening; and configuring the container to sit on top of the drinking container to allow liquid to drain from the at least one opening into the drinking container.

According to yet another aspect of the present invention, an apparatus for brewing a brewing substance with a liquid comprises: a container for storing the liquid, the container including at least one aperture for dispensing the liquid therefrom; a heat sensitive film packaging bag containing the brewing substance and a layer of filter paper covering the packaging package to form a subassembly disposed in a position covering the at least one opening in a container configured to sit on top of a drinking container to allow liquid to drain through the at least one opening into drinking containers.

According to yet another aspect of the present invention, a method of manufacturing a brewing device comprises the steps of: configuring a container to store liquid for brewing and dispensing the liquid through at least one opening therein; encapsulating the brewing substance with a heat sensitive film layer; covering with filter paper Encapsulating the brewing substance to form a subassembly; positioning the subassembly within the container overlying the at least one opening; and configuring the container to sit on top of the drinking container to allow liquid to drain from the at least one opening into the drinking container.

Description of drawings

Figure 1 is an exploded, isometric view of components of a brewing apparatus suitable for practicing one aspect of the present invention;

Fig. 1A is a schematic cross-sectional view of a brewing substance packaging bag suitable for the embodiment of Fig. 1;

Figure 2 is a schematic cross-sectional view of an assembled brewing apparatus according to the inventive aspects depicted in Figure 1;

Figure 3 is an isometric view of a brewing vessel suitable for use in the embodiment of Figure 1;

4A-4C are top, side and isometric views of a filter paper seal bag for containing brewing substances suitable for use in the embodiment of FIG. 1;

Fig. 5A-Fig. 5C are the top, side and isometric views of the thermosensitive film layer applicable in the embodiment of Fig. 1;

Figure 6 is another cross-sectional view of an assembled brewing apparatus suitable for practicing an aspect of the present invention;

6A and 6B are more detailed cross-sectional views of portions of the assembled brewing apparatus of FIG. 6;

Fig. 7 is a schematic diagram describing container nesting applicable to the embodiment of Fig. 1;

Figure 8 depicts a schematic diagram of a nest of assembled brewing devices;

Figure 9 is an exploded, isometric illustration of components of a brewing substance containing subassembly suitable for use in an embodiment of another aspect of the invention;

10A-10C are top, side and detailed cross-sectional views of the assembled subassembly depicted in FIG. 9;

11A and 11B are top and cross-sectional side views of an assembled brewing apparatus according to another aspect of the present invention;

Figure 11C is a more detailed cross-sectional view, partially broken away, of the assembly depicted in Figures 11A and 11B;

Figures 12A and 12B are top and bottom isometric views of a container suitable for use in the embodiment of Figures 11A and 11B;

13A and 13B are top and cross-sectional side views of an assembled brewing apparatus according to yet another aspect of the present invention;

13C-13E are cutaway cross-sectional views of certain details of the assembly depicted in FIGS. 13A and 13B ;

Figures 14 and 15 are bottom and top cut-away isometric views of the discharge device suitable for use in the embodiment of Figures 13A and 13B;

Figure 16 is an exploded, isometric view of components in the embodiment of Figures 13A and 13B;

Figure 17 is a schematic isometric view of the assembled brewing device seated on the drinking vessel;

Figure 18 is a schematic diagram of an exemplary assembled brewing equipment nest;

Figure 19 is an exploded, isometric schematic view of components of a brewing apparatus suitable for practicing yet another aspect of the present invention;

Figure 20 is an isometric, cut-away bottom view of the brewing apparatus depicted in Figure 19;

Figure 21 is an exploded, isometric illustration of components of a brewing apparatus suitable for practicing yet another aspect of the invention.

Detailed ways

A suitable embodiment of one aspect of the invention is depicted in Figures 1 to 6B. Figure 1 is an exploded, isometric view of the components of a brewing device suitable for use in a microwave oven. Referring to Figure 1, a pod 10 contains a brewing substance (not shown), which may be, for example, coffee grounds, ground tea leaves, chocolate or other flavored powders, and the like. The brewing substance may even include a combination of milk powder and sugar or a sugar substitute. The different views of FIGS. 4A-4C provide a more detailed description of a suitable brewing substance pack 10 . As shown in the cross-sectional view of Figure 4B, the brewing substance is contained within the top and bottom filter paper layers 12 and 14, respectively.

In general, filter paper layers 12 and 14 may be composed of, for example, Manila hemp, cellulose, and thermoplastic fibers. Crompton #47604 or equivalent paper material was found to provide a suitable filter paper layer. Other suitable filter paper characteristics include: a weight of 21.0 milligrams per square inch, an air permeability of 50 cubic meters per minute per square meter, a thickness of 89 microns, a wet burst strength of 22 kPa, a dry tensile strength of MD98 g/mm and CD34 g/mm mm, and a seal strength potential of 377g/50mm. The food grade of the paper should preferably comply with FDA standard 21 CFR 176.170.

As shown in FIGS. 4A-4C , filter paper layers 12 and 14 may be in the form of a circle, for example, approximately 2.9 inches in diameter. The brewing substance may be disposed over the bottom paper layer 14 , preferably forming a pile with the highest point in the center of the paper 14 . The top paper layer 12 may be positioned over the brewing mass with its circumferential edges aligned with the circumferential edges of the paper 14 . The top and bottom paper layers 12 and 14 may be sealed together around their perimeters to form the bag 10 having a relatively flat annular rim 16, for example, about 0.25 inches wide and about 8 mils thick. The sealing process can be performed by any commercial method. FIG. 4C depicts an exemplary package 10 of generated three-dimensional isometric views.

Returning to Figure 1, the brewing device comprises top and bottom layers 18 and 20, respectively, made of heat sensitive films. In this embodiment, the top and bottom layers 18 and 20 are the same or similar in shape. Views of exemplary top or bottom thermally sensitive film layers are shown in Figures 5A-5C to provide more detail thereof. It should be understood, however, that the membrane layers 18 and 20 need not be preformed into the domed shape shown prior to integration with the coffee pad. Due to their integration with pack 10, film layers 18 and 20 may be slightly corrugated flat circular blank pieces. A suitable thermally sensitive material for film layers 18 and 20 is ethylene vinyl acetate, such as a copolymer film having a thickness of about 0.00225 inches (0.057 mm). This material is commercially sold under the LOMEL trade name by J.D. Rasner & Co of Beachwood, Ohio, USA, and is food grade compliant with FDA standards. The top and bottom film layers 18 and 20 can be manufactured to melt or rupture at different temperatures. For example, the top membrane layer 18 may be manufactured to rupture at approximately 160°F, while the bottom membrane layer 20 is manufactured to rupture at approximately 180°F. It should be understood that other rupture temperatures may be used for the top and bottom film layers 18 and 20 without departing from the basic principles of the invention.

As shown in FIGS. 5A-5C , for example, the top and bottom film layers 18 and 20 may each be shaped as a circle approximately 2.9 inches in diameter with a relatively flat edge 22 around its perimeter having a width of approximately 0.25 inches. The central portion 24 of each film layer 18 and 20 can be shaped to substantially conform to the shape of the bag 10 so that the top and bottom film layers 18 and 20 can be respectively disposed on the bag 10 as shown in the cut-away cross-sectional schematic view of FIG. 1A . top and bottom surfaces. However, as explained in the preceding paragraph, membrane layers 18 and 20 can take other shapes without departing from the basic principles of the invention. Referring to FIG. 1A , film layers 18 and 20 may be heat sealed around their perimeter at edge 22 to form a sealed interface 28 . This can be achieved by any known heat sealing technique such as ultrasonic heating, for example. The bag 10 containing the brewing substance 26 may thus be sealed within the membrane layers 18 and 20 so as to form a subassembly 30 of the encapsulated brewing substance 26 . The process of encapsulating the brewing substance in the subassembly 30 as described above in this application may be performed under a nitrogen atmosphere.

Returning to FIG. 1 , the brewing apparatus further includes a brewing basket or container 40 . In this embodiment, container 40 may be fabricated from approximately 0.020 inch thick high impact polystyrene material and configured in a square or rectangular cross-sectional shape with a tapered cross-sectional area from top to bottom. Exemplary dimensions of the container 40 of this embodiment include approximately 4.7 inches on each side of the top and a height of 2.1 inches. Although the present embodiment uses a rectangular cross-sectional shape for the container 40, it should be understood that other cross-sectional shapes, such as a cylinder for example, may be used without departing from the basic principles of the invention. To provide additional structural strength and for design purposes, container 40 may include a variety of differently shaped profiles along the sides and bottom.

At the bottom of the brewing vessel 40 is a cavity 42 which is shown more clearly in the cross-sectional view in FIG. 2 and in the isometric view in FIG. 3 . As shown in FIG. 2, in this embodiment, the cavity 42 may be configured in a frusto-conical shape to accommodate the subassembly 30, but other shapes are also sufficient. As shown in FIG. 3 , at the bottom of the cavity 42 is an opening 44 that is circular in configuration and surrounds the bottom portion of the relatively large cavity 42 . Figures 6, 6A and 6B illustrate the container 40 of this embodiment in more detail. 6 is another cross-sectional view of container 40 showing protrusions or feet 46 extending from the bottom surface and upon which container 40 may rest in a vertical orientation. The feet 46 can also be seen in FIGS. 2 and 3 . The schematic cross-sectional view of FIG. 6A reveals one of the feet 46 in greater detail.

In this embodiment, the feet 46 are disposed along the outer bottom edge and substantially aligned with the four corners of the rectangular cross-section of the container 40 . However, it should be understood that the feet 46 may be disposed about the bottom edge in any spaced pattern. Although four feet 46 are described in this embodiment, it should be understood that three feet 46 may be used as well, as long as they are properly spaced from each other about the outer bottom edge of container 40 .

To complete the assembly of the brewing apparatus, the sealed subassembly 30 is disposed within the cavity 42 as shown in the cross-sectional views of FIGS. 2 and 6 . As shown in FIG. 6B , which is a more detailed cut-away cross-sectional view of the subassembly 30 resting within the cavity 42 , the rim 22 of the subassembly 30 is seated circumferentially around the edge 50 of the bottom surface of the container 40 . Note that the weight of the subassembly 30 creates a seal against the side walls of the cavity 42 during the brewing process, as will be better understood from the description below in this application. As an alternative embodiment, bag 10, film layers 18 and 20, and container 40 may be integrated in a single step.

Figure 7 depicts a cross-sectional view of the nesting of a plurality of brew baskets 40 for storage prior to the assembly process described above in this application. Note that the baskets 40 are shaped to fit snugly within each other so that they take up little space during storage. Figure 8 depicts a schematic cross-sectional view of a nest of multiple assembled brewing devices that may be stacked closely within each other. Thus, stacks of multiple assembled brewing devices can be packaged together for retail sale without taking up too much space on retailer or consumer shelves.

After purchasing the retail package, the consumer removes the brewing unit from the package and fills the container 40 to the appropriate level with the desired liquid, like water for example. If the brewer unit is to be used for single-cup brewing of liquids, the consumer can fill container 40 with, for example, 8 or 9 ounces of liquid. To this end, a fill line may be provided on one or more inner sides of the container 40 . Note that the weight of the liquid within the basket 40 can press the subassembly 30 firmly against the walls of the cavity 42 as shown in FIG. 6B . Subsequently, as shown in Figure 17, the brewer unit may be placed on top of a drinking vessel, which may be a cup, for example, so that the bottom surface of the cavity 42 rests around the top edge of the cup. Note that aperture 44 falls into the top opening of the drinking container and that foot 46 will center aperture 44 over the opening of the cup and prevent container 40 from sliding over the top edge of the cup.

Thereafter, the brewer unit and cups can be set in the microwave for heating, which may take several minutes, depending on the power of the microwave. In this example, when the liquid temperature reaches the rupture temperature of the top film layer 18, which may be about 160 F, the film layer 18 begins to thin and rupture, resulting in delamination of the layer 18 that begins at the rupture point and moves toward the outer boundary, and The filter paper layer 12 is exposed. At this point, the hot liquid will penetrate the paper layer 12 and mix with the brewing substance. Note that the bottom film layer 20 has not been ruptured, thus allowing the hot liquid to sit and wet the entire volume of the particles of brewing substance 26, allowing a more even input of the aroma of the brewing substance into the brewing liquid.

The brewing liquid will continue to be heated by the microwave. Subsequently, as the liquid reaches the rupture temperature of the bottom layer 20, for example about 180[deg.]F. The bottom layer 20 will rupture in a similar manner to the top layer 18, thus dispensing the brewed liquid by gravity through the filter paper 14 and openings 44 into the drinking vessel. The brewing process can take several minutes after one microwave cycle. Thereafter, the brewing liquid is in a drinking vessel. Note that the top and bottom filter paper layers 12 and 14 keep the particles of brewing substance 26 within the volume of the bag 10 to ensure full input of aroma during brewing. For example for the brewing of coffee, the brewing cycle will take on the order of 3-5 minutes. For other brews, brewing times can vary depending on the liquid and brewing substance used. Brewing time will also vary depending on the power of the microwave used.

The advantages of the foregoing embodiments are as follows: Encapsulation of the brewing substance charge pack within the heat sensitive film layer provides for preservation of each unit's brewing substance charge for a certain period of time after the retail package is opened. No user interaction is required to open or remove the film seal of the packet as this will occur automatically during the brewing process. In addition, the staged exposure of the brewing substance charge allows for capillary action to first allow a small amount of liquid to penetrate the brewing substance gently before the higher flow rate brewing process begins, thus allowing a greater portion of the liquid in the reservoir to flow through the wet brewing substance charge.

Furthermore, this embodiment holds the brewing substance in a stable shape within the filter bag, thus keeping the water resistance uniform and predictable, which is preferred for consistent extraction from one brewer to the next. Also, the brewing substance charge is maintained at a position where the fluid discharge pressure is high. Note that the brewing substance is fully contained within the filter paper bag, which prevents the brewing substance from entering the reservoir.

Figure 9 is an exploded, isometric view of the components of a subassembly unit 60 for containing brewing substances suitable for use in an alternative embodiment of the brewing apparatus. Referring to Figure 9, top and bottom thermally sensitive film layers 62 and 64 respectively enclose a brewing substance 66, which in this embodiment may be coffee grounds, for example. Membrane layers 62 and 64 may be of the same or similar type and construction as described above in this application for layers 18 and 20, and may be heat sealed together around the boundaries of their edge portions to fully encapsulate the brewing substance. In addition, top and bottom filter paper layers 68 and 70, respectively, are disposed and attached to the surfaces of the respective top and bottom film layers 62 and 64 to form subassembly 60 shown in the top and bottom views of FIGS. 10A and 10B , respectively. Filter paper layers 68 and 70 may be of the same or similar type and construction as described above for paper layers 12 and 14 herein. FIG. 10C is a more detailed cross-sectional view of layers 62 , 64 , 68 , and 70 of subassembly 60 .

In the above manner, the brewing substance encapsulation subassembly may be formed as a separate subassembly and then subsequently attached to the reservoir structure by, for example, ultrasonic, vibration, laser, and heat welding, as described in more detail in connection with FIGS. 11A-C . The described layout allows the formation of the machine using relatively common subassemblies. By contrast, coffee ground packaging in existing concepts would necessarily require a custom machine capable of handling molded reservoirs in addition to paper and plastic layers in a nitrogen atmosphere. For instant subassemblies, only their manufacture is carried out in a nitrogen atmosphere, not the components of the complete brewer unit. A 100% nitrogen environment is preferably provided during the assembly process and near the inside of the package to exclude potentially harmful oxygen.

FIGS. 11A and 11B depict top and side views of the reservoir basket 72 containing the brewing substance subassembly 60 disposed on top of a bottom liquid diffusion member 74 disposed on top and bottom of FIGS. 12A and 12B , etc. Shown in greater detail in the larger view. In this alternative embodiment, reservoir 72 is square or rectangular in cross-section and bottom diffuser 74 is cylindrical in shape and contains spokes 76 affixed between a point 78 from the border of the part to the center of the part. The spokes 76 are evenly spaced to the opening boundary so as to create wedge-shaped openings through which liquid dispensed from the reservoir 72 flows during the process.

11C is an enlarged cross-sectional view showing how the rim 73 of the subassembly 60 rests circumferentially on the protrusion 76 of the reservoir 72 disposed about its bottom surface. As mentioned above, the edge 73 of the subassembly 60 may be attached to the protrusion 76 of the reservoir structure 72 by, for example, ultrasonic, vibration, laser or thermal welding. Also, as shown in FIGS. 12A and 12B , feet 80 may be formed or affixed near the bottom border of reservoir 72 , preferably aligned with the corners of its rectangular cross-section. The cylindrical diffuser 74 may extend a distance below the foot 80 so that when the reservoir 72 rests on the top edge of the drinking vessel during brewing as described above in this application, the cylindrical diffuser 74 will fall on the drinking vessel. inside the container opening. The open area of the passageway from the reservoir 72 or the diffuser 74 on which the brewing substance subassembly 60 is disposed is large and less restricted in instant embodiments. Larger openings will create more even contact between water and coffee grounds, ultimately providing improved extraction as well as shorter brew times.

A few points about the proposed subassembly structure are as follows: a layer of filter paper on the top prevents the buoyant grinds from rising into the reservoir (i.e. keeps the grinds in the brew chamber for optimal extraction); the top and bottom The upper layer of filter paper facilitates thermal fusing, as the paper prevents the molten plastic film from adhering to the heated mold (it is believed that the same benefit can be observed during ultrasonic welding); as above, the top and bottom dual thermal film The construction provides a freshness seal, especially one that does not require user intervention to open; the difference in melting temperature between the bottom membrane layer and the upstream top membrane layer serves two functions: (a) guarantees that the lower membrane is It loses temperature through the grind so that the two membranes have the same melting point is not guaranteed), and (b) the lower membrane temporarily retains hot water in the brewing chamber to ensure a good infusion of the grind.

As mentioned above, a suitable material for the reservoir 72 is expanded polystyrene (a.k.a., EPS, expandable polystyrene), which can be molded into the desired configuration or shape due to the Superior insulation properties. Using this material will shorten the microwave heating time of the brewed liquid compared to denser plastic materials. Also mentioned above, multiple brewers can be nested for efficient packaging. The use of sealed multi-pack retail containers (not shown) tends to provide a freshness seal (in addition to the individual encapsulation of coffee within each "brewer" provided by the two EVA film layers within each subassembly). The packaging of the individual subassemblies allows fresh packaging of the multi-pack container to be opened and also maintains the freshness of the brewing substance within the individual subassemblies.

An exemplary embodiment of a brewing apparatus according to another aspect of the present invention is depicted in FIGS. 13A-16 . Referring to Figures 13A and 13B, which depict top and cross-sectional views of the brewing apparatus, the reservoir 90 is shown as having a square cross-section with a cross-sectional area that tapers from top to bottom. Attached to the bottom of the reservoir 90 is a brewing chamber 92 that is cylindrical in shape. The bottom of the reservoir slopes towards a drainage area 94 forming a passage between the reservoir 90 and the brewing chamber 92 . The reservoir 90 is designed to hold a brewing liquid, which may be water, for example. Liquid is typically added and then heated in reservoir 90 within the microwave. Pre-heated liquid can be added to speed up the microwave heating process. Extremely hot liquids can be used to avoid microwave use altogether.

As mentioned above, the reservoir 90 is preferably square or rectangular in cross-section, but may be of any shape. A square or rectangular shape maximizes the capacity of the reservoir for the space used by the microwave. The shape of the brewing device of the present invention is preferred as it allows the brewer to fit the device in the small compartment of any microwave oven. For example, comparing circular and square reservoirs respectively having equal diameter and side length and equal height, the volumetric capacity of the square reservoir is greater. It thus follows that a square reservoir having the same volumetric capacity and having the same side length as the diameter of a circular reservoir has a smaller height. This is advantageous if the microwave oven used is of compact design. However, the main benefit of nesting is to potentially allow a greater number of units to fit within a limited area of a retail shelf. Many different shaped reservoirs can be nested with the same vertical effect. Nested circular shapes are preferred because they can be positioned in an infinite continuum, whereas rectangular shapes only have four nested positions at 90° intervals.

Reservoir 90 may be made of transparent or translucent material. This allows visual observation of the liquid level within the reservoir. A preferred material is polypropylene. Polypropylene has a melting temperature of about 210°F. As shown in FIG. 13B , the reservoir 90 may include a reinforced seam 91 . Seam 91 may serve multiple purposes. First, the seam 91 can increase the rigidity of the reservoir 90, preventing it from breaking easily. Second, seam 91 can be positioned as a fill line, allowing the user to know when the desired volume of liquid has been poured into reservoir 90 .

Reservoir 90 may include a series of feet 93 on its bottom surface. Feet 93 may have variable configurations. The feet 93 of this embodiment are similar to the feet 80 shown in Fig. 12B, in that each foot is formed by a pair of parallel protrusions. The protrusions are bent toward each other at the border of the reservoir and meet (ie, round). At the opposite end, the protrusion abuts the wall of the brewing chamber 92 (see Figure 14). In alternative embodiments, each foot may be a single protrusion. The feet 93 function to provide strength and rigidity to the base of the reservoir and act as a support for the brewer on the cup or mug. The extended length of each foot allows a single size custom made brewer to be placed stably on drinking vessels of different diameters. Thus, the brewer is universal for several shapes and sizes of cups and teacups. In other embodiments, feet 93 are not required.

Drain assembly 94 acts as a passageway for liquid between reservoir 90 and brew chamber 92 . Referring again to Figure 14 which is a cut-away isometric bottom view of the interior of the brewing chamber 92 and to Figure 15 which is a cut-away isometric top view of the base of the reservoir 90, both of which show the drainage in more detail Component 94. Drain assembly 94 may include an aperture 96 in the base of reservoir 90 . Opening 96 may be covered with a thermally sensitive film seal 98 described in more detail below. The drain assembly may also include a diffuser extension 100 extending from the base of the reservoir 90 down through the aperture 96 . Diffusion epitaxy 100 may be integrally formed with reservoir 90 .

Diffusion epitaxy 100 may include a plurality of spokes 102 extending from a central axial member 104 to the walls of aperture 96 oriented downwardly and transversely to aperture 96 (see FIG. 15 ). The configuration of axial members 104 and spokes 102 extends below aperture 96 (see FIG. 14 ) to form a wedge-shaped opening area for brewing chamber 92 . The axial members 104 and spokes 102 defining these wedge-shaped opening areas act as a structural support frame. The supportive nature of the diffusion extension 100 also prevents the layer of filter paper positioned below the drain assembly 94 from deforming upward during packaging or handling of the brewer, as will become more apparent from the description below in this application. The open area or aperture in diffuser extension 100 in combination with the support frame allows liquid flowing through drain assembly 94 to spread radially through brew chamber 92 rather than being concentrated at a location directly below reservoir aperture 96 . The presence of the diffuse structure is important for the taste of the brewing liquid as well as for the uniform brewing time of all the brewing substance particles in the brewing chamber 92 .

In this embodiment, the brewing chamber 92 is defined by a circular wall extending downwardly from the bottom of the reservoir 90 . However, the brewing chamber 92 may have any shape. The brew chamber holds a brewing substance 106, which may be coffee grounds, for example. The grind size of the coffee grounds can be varied to meet the desired brew profile. Grind size can also vary depending on the type of caffeinated or decaffeinated coffee used. Filter paper 108 supports brewing substance 106 within brewing chamber 92 . If not for the presence of a paper filter 108 and another heat sensitive film seal 110 as described below, the brewing chamber 92 is open at its base. In one embodiment, the height and diameter of the open base of the brew chamber are approximately 0.5 inches and 2.25 inches, respectively. In comparison, in the same embodiment (4.5:1 ratio), the diameter of the opening 96 in the bottom of the reservoir may be about 0.5 inches. This ratio can be adjusted to achieve the desired brewing characteristics.

As mentioned above, the brew chamber 92 holds a charge of brew substance 106, which may be coffee, through which a hot brew liquid, like water, will flow. The particle or grind size of the brewing substance charge can vary depending on the brewing substance used. Grind size can also be modified to alter the residence time of liquid within the brew chamber 92 and to alter the liquid flow characteristics through the grind charge. Instead of using different types or aromas of brewing substances, substance supplements or substitutes may be used. Sweeteners or powdered dairy products can be mixed with the grind. As an alternative embodiment, sweeteners or powdered dairy products may be placed as separate layered layers within the brewing chamber 92 . Layered layers can be placed in any order. The layered layers are separated by filter paper layers 108, heat sensitive film seal layers 110, or no material at all. The charge 106 of brewing substance particles and possible supplements may be extruded into a disc shape using a conventional extruder.

A paper filter layer 108 is placed below the brewing substance charge 106 to prevent the grounds from entering the brewer's cup or mug. The filter 108 has various characteristics, such as fiber type, size, denier, length, and configuration. These features can be varied to achieve the desired brewing situation. For example, the residence time in the brewing chamber can be controlled. Furthermore, the angle at which water travels radially within the brewing chamber can be controlled.

As shown in the more detailed cross-sectional view of Figure 13D, the paper filter layer 108 may be attached to the wall 112 of the brew chamber 92 using an ultrasonic bonding process. The brewing chamber wall 112 is formed so as to define a lowermost extreme point 114 . The paper filter layer contacts the brew chamber at these points 114 and operates to form the connection as shown in Figure 13D. This bonding process can be repeated on the lowest wall of the diffusion epitaxy, as shown in the more detailed cross-sectional view of Figure 13E. As shown in FIG. 13E , diffusion epitaxy 100 defines a circular bonding surface 116 at its base. Other methods of joining the filter 108 to the brewer device may also be used, such as glue or heat deformation of one or both joining materials.

In an alternative embodiment, the brewing substance charge 106 is contained in a subassembly bag that includes filter material as described above in this application. As an alternative, the bag may also consist of the film seal material described above.

In this embodiment, the thermal film seal is placed over the opening 96 in the bottom of the reservoir 90, thereby blocking the opening (see layer 98 in FIG. 13C ), or in a position below the filter paper layer 108, (see Layer 110 in Figure 13D) is either in two positions. Thermal film seals can serve one or more functions. First, thin films can serve as heat-sensitive valve devices. At room temperature, the seal acts as a physical barrier between the two regions. The damage begins as the liquid heats up in the area on one side of the film. A set amount of time elapses before the hot liquid heats to rupture or fail the membrane. This amount of time can be a function of several factors:

1) The time it takes for the microwave to raise the temperature of the liquid to a point where the film begins to damage or crack. In one embodiment, the "critical temperature" may be from about 195°F to 205°F, and

2) The durability of the film at adjacent temperatures, which can be a function of the chosen film material, film thickness, and overall film dimensions. Preferred film materials are Ethylene VinylAcetate or Lomel. The melting or rupture point of this material is about 160[deg.]F. Preferred film thicknesses are from about 0.0015 inches to 0.0030 inches. Films are available in colored or clear form.

Preferably, the thermally sensitive film layer 98 fails such that the opening or aperture 96 previously covered by the seal 98 is almost completely open. Combined with this large degree of shrinkage of the film 98, the film also does not break into pieces so that no small pieces of sealing material will be received in the consumer's cup or mug.

One benefit of using a thermally sensitive film layer 110 below the filter paper layer 108 is to increase the residence time of hot liquid in the coffee grounds. When two film seals 98 and 110 are used, they can be designed to have the same or different failure properties. In one brewing method, the upper seal membrane 98 is designed to fail at 180°-190°F and the lower seal is designed to fail at 160°-170°F, but these temperature profiles can be reversed. The failure temperature can be controlled by the film material used and the thickness of the material.

A second function that the double membrane layers 98 and 110 can provide is to seal the coffee grounds from the atmosphere. Moisture, odors or contaminants may be present in the ambient air and should be kept away from the coffee grounds. The double membrane layer can be gas permeable, but can also be designed to provide the necessary hermetic packaging. The double membrane layer increases the shelf life of the brewer for storage purposes at the user's home. It locks in fresh ingredients.

In embodiments where the reservoir opening 96 is covered with a membrane seal 98 and the membrane seal 110 is disposed below the filter paper layer 108, an alternative membrane material, such as foil, may be used in one location if the thermally sensitive properties are not necessary. Membrane seals 98 and 110 may be held in place with glue, using an ultrasonic bonding process similar to that described above for filter 108, by fasteners such as O-rings, or by melting the membrane to the brewer. FIG. 13C shows membrane layer 98 joined to the bottom of the brewer at an annular protrusion or raised rib 120 surrounding drainage area 94 near opening 96 . One or more ribs 120 protruding from the reservoir floor provide a bonding surface for the membrane seal 98 . Below the filter paper layer 108, the membrane seal 110 is bonded to the brew chamber wall 112 at a point 122 (see Fig. 13D) which extends down and to the outside of the point where the filter is bonded.

Referring to the exploded, isometric view of the brewing apparatus of this embodiment shown in FIG. 16, a preferred method of manufacturing the brewing apparatus includes sealing the opening 96 on the bottom of the reservoir 90 with a heat sensitive film while the reservoir 90 is in an upright position. position; and then rotate the reservoir 90 180 degrees so that the bottom is upright. In this rotated position, the brewing substance charge 106 is placed in place on the brewing chamber 92; the paper filter layer 108 is then placed in place and attached to the points 114 and 116 described above in this application; and then the second membrane Sealing layer 110 is disposed over the opposite side of the filter from brewing substance charge 106 and is affixed to brewing chamber 92 wall 112 at point 122 .

Figure 17 is a schematic illustration of a brewing device 130 with a cylindrical reservoir engaging a teacup 132 for brewing in a microwave oven. The liquid fill capacity of the liquid reservoir 130 for single-serve brewing is between 8 and 9 ounces (an 8 oz fill tends to yield 7 to 7-1/2 ounces of drinkable coffee, whereas a 9 oz fill yields approximately 8oz of potable coffee). As mentioned above, it is believed that the square cross-sectional shape of the reservoir allows for better utilization of available product shelf space, allowing both retailers and users to increase nesting efficiency.

Figure 18 shows suggested retail packaging for brewers in an exemplary nested or stacked configuration. Thus, nested brewers can be stored and sold in metal or paper cans. The outer ear cap can provide an additional seal to prevent damage.

Figures 19 and 20 depict exemplary brewing equipment suitable for practicing yet another aspect of the present invention. Fig. 19 is an exploded, isometric view of the components of this embodiment. Many components of the embodiment of FIG. 19 are identical in result and function to those described above for the embodiment of FIGS. 13A-16 . These identical components will not be described further, and the reference numerals remain the same for this embodiment. Referring to FIG. 19 , a spring-loaded valve assembly including a spring 134 and a valve 136 is disposed at the opening 96 in the brewing chamber 92 . One end of the spring 134 is attached to the valve 136 , and the other end is attached to the periphery of the opening 96 . Valve 136 includes a flat circular central surface 137 and three resilient feet 138 affixed at points approximately 120° apart around surface area 137 . The distal end of foot 138 includes a stretched surface area 140 transverse to foot 138 . As shown in the cut-away isometric view of FIG. 20 , surface regions 140 of feet 138 are attached to regions of the bottom of reservoir 90 within brew chamber 92 .

Prior to brewing, spring 134 remains in a compressed state to allow flat surface 137 of valve 136 to cover and seal aperture 96 of reservoir 90 . In this embodiment, the spring 134 is held in compression by a temperature sensitive wax material which can also be used to attach the spring 134 to the valve surface 137 . Wax materials used in this example include amide waxes, such as ethylene bisstearamide, and long chain ketones, such as aromatic ketones. It should be understood, however, that other components may also be used for the wax.

During brewing, as the temperature of the liquid in the reservoir increases, the wax material eventually melts, allowing the spring 134 to extend to an uncompressed state. A suitable melting temperature for the wax material may be about 160 to 190 degrees Fahrenheit. This extension of the spring 134 forces the surface area 137 away from the aperture 96 thereby creating an opening or passage for heated liquid to pass from the reservoir 90 into the brew chamber 92 and mix with the brewing substance 160 . The feet 138 act as guide ledges to prevent the valve surface 137 from floating back into the sealing position after the wax has loosened. Eventually, the bottom film seal 110 ruptures, allowing hot brewing liquid to be dispensed through the paper filter layer 108 into the cup 132 . In this embodiment, the upper film seal layer 98 can be dispensed with since the valve assembly itself is temperature sensitive and functions in a similar manner.

An exploded, isometric view of components of a brewing apparatus suitable for practicing yet another aspect of the invention is shown in FIG. 21 . Referring to Figure 21, this embodiment includes a cylindrical reservoir 150 having a small liquid distribution opening (not shown) in its bottom, which may be made of polypropylene, for example. The dispensing opening within the reservoir 150 may be covered and sealed using a top thermal sensitive film seal 152, which may be made of foil, for example. A valve assembly 154, similar to the valve assembly described above in this application, may be affixed to the outside bottom of the reservoir 150 so as to cover and seal the dispensing opening. For example, valve 154 may be made of polycarbonate material and operate in a similar manner as valve 136 .

In addition, a brew funnel 156, which may also be made of, for example, polypropylene, is attached to the base of the reservoir 150. The brewing funnel 156 includes a brewing chamber for supporting a layer of filter paper 158 and a charge of brewing substance 160 therein. The bottom of the brew funnel 156 includes at least one opening for dispensing brewing liquid therethrough. A filter paper layer 158 may be provided, and possibly bonded, to an annular protrusion 162 formed along the inner boundary of the brewing funnel 156 , and a charge 160 may be provided above the filter paper 158 . A bottom thermal film seal 164 may be attached to the bottom of the funnel 156 to cover and seal at least one opening thereof. The embodiment of FIG. 21 may operate in a manner similar to that described for the embodiments of FIGS. 19 and 20 .

Although the invention has been described above in connection with a number of embodiments, it should be understood that this representation is provided strictly by way of example, without any intent to limit the invention in any way. Accordingly, the present invention is not to be limited by the description of the embodiments presented hereinabove, but is to be construed in breadth and breadth in light of the recitation of the appended claims.

Claims (40)

1. Apparatus for brewing brewing substances from liquids, said apparatus comprising: a container for storing said liquid, said container comprising at least one aperture for dispensing liquid therefrom; a filter paper seal bag containing the brewing substance; and a heat sensitive film layer encapsulating the sealing pack disposed within the container at a location covering the at least one opening, the container configured to sit on top of a drinking container to allow liquid to flow from the at least one opening An aperture discharges into the drinking vessel. 2. Apparatus according to claim 1, characterized in that said package is secured within said container. 3. The apparatus of claim 1, wherein the container includes a cavity configured to receive the package, and wherein the package is disposed at the cavity. 4. The apparatus of claim 3, wherein the cavity is located at the bottom of the container; and wherein the cavity comprises a single opening covering a substantial area of the cavity. 5. The apparatus of claim 3, wherein the package includes a substantially flat rim around its boundary; wherein the container includes a protrusion disposed around a boundary of the cavity; and wherein the The edge of the packaging package seats on the protrusion. 6. Device according to claim 5, characterized in that the edge of the package is fixed on the protrusion. 7. The apparatus of claim 1, wherein the sealed package comprises a top surface and a bottom surface; and wherein the encapsulated package comprises: a first thermally sensitive film layer covering the top surface of the sealed package; and A second layer of heat sensitive film covering the bottom surface of the sealed pack, the first and second layers being attached together along their outer borders to encapsulate the sealed pack within the first and second layers. 8. The apparatus of claim 7, wherein said first and second thermally sensitive film layers have different rupture temperatures. 9. The device according to claim 7, wherein the rupture temperature of the first heat-sensitive film layer is lower than the rupture temperature of the second heat-sensitive film layer. 10. The apparatus of claim 7, wherein said first thermally sensitive film layer has a rupture temperature of about one hundred and sixty degrees Fahrenheit and said second thermally sensitive film layer has a rupture temperature of about one hundred and sixty degrees Fahrenheit. Eighty degrees Fahrenheit. 11. The apparatus of claim 1, wherein the container is configured with a plurality of feet to prevent the container from sliding off when seated on top of the drinking container. 12. The device of claim 1, wherein the container is configured to allow nesting of multiple containers by placing one inside another. 13. The apparatus of claim 1, wherein the container is configured to have a rectangular cross-section that tapers from top to bottom. 14. The apparatus of claim 1, wherein said brewing substance comprises coffee grounds and said liquid comprises water. 15. The apparatus of claim 1, wherein: the container is configured to store a single serving quantity of liquid; and wherein the sealed pack contains a single serving charge of brewing substance. 16. The device according to claim 1, wherein the container and the heat-sensitive film layer are made of materials suitable for microwave heating. 17. A method of manufacturing brewing equipment, said method comprising the steps of: a container configured to store liquid for brewing and to dispense said liquid through at least one opening therein; Encapsulate the filter paper seal bag containing the brewing substance with a heat-sensitive film layer; disposing the package within the container at a location covering the at least one aperture; and The container is configured to sit on top of a drinking container to allow liquid to drain from the at least one aperture into the drinking container. 18. The method of claim 17, comprising the step of securing said package within said container. 19. The method according to claim 17, characterized in that: comprising the steps of: configuring the bottom of the container with a cavity formed to receive the package; and disposing the package at the cavity. 20. The method according to claim 17, wherein the encapsulating step comprises: Covering the top surface of the sealed package with a first heat-sensitive film layer; covering the bottom surface of the sealed bag with a second heat-sensitive film layer; and The first and second layers are attached together along their outer boundaries to encapsulate the sealed packet within the first and second layers. 21. The method of claim 20, wherein the top and bottom surfaces of the sealed pack are covered with heat-sensitive film layers having different rupture temperatures. 22. The method according to claim 20, wherein: the top surface of the sealed package is covered with a first heat-sensitive film layer having a first rupture temperature; and wherein the bottom surface of the sealed package is covered with a layer having a temperature higher than The second heat-sensitive film layer of the second rupture temperature of the first rupture temperature. 23. The method of claim 20, wherein the top surface of the sealed pack is covered with a first heat-sensitive film layer having a rupture temperature of about one hundred and sixty degrees Fahrenheit; wherein the bottom surface of the sealed pack is covered with There is a second thermally sensitive film layer having a rupture temperature of approximately one hundred and eighty degrees Fahrenheit. 24. The method of claim 17, comprising configuring the container with a plurality of feet to prevent the container from sliding off when seated on top of the drinking container. 25. The method of claim 17, comprising configuring said containers to allow nesting of multiple containers by placing one inside another. 26. The method of claim 17, comprising configuring the container to have a rectangular cross-section that tapers from top to bottom. 27. The method of claim 17, comprising forming said container and said thermally sensitive film layer from a material suitable for microwave heating. 28. Apparatus for brewing a brewing substance from a liquid, said apparatus comprising: a container for storing liquid, said container comprising at least one aperture for dispensing liquid therefrom; heat-sensitive film packaging packs containing brewing substances; and a layer of filter paper covering the package to form a subassembly disposed within the container at a location covering the at least one opening, the container configured to sit on top of a drinking container to allow liquid to flow from the The at least one opening discharges into the drinking container. 29. The apparatus of claim 28, wherein said subassembly is secured within said container. 30. The device according to claim 28, wherein the package comprises: forming a first heat-sensitive film layer on the top surface; and A second thermally sensitive film layer forming the bottom surface, said first and second layers are attached together along their outer boundaries to encapsulate the brewing substance. 31. The apparatus of claim 30, wherein said first and second thermally sensitive film layers have different rupture temperatures. 32. The apparatus of claim 28, wherein said brewing substance comprises coffee grounds and said liquid comprises water. 33. The apparatus of claim 28, wherein: the container is configured to store a single serving amount of liquid; and wherein the capsule contains a single serving charge of the brewing substance. 34. The apparatus according to claim 28, wherein said container and said heat-sensitive film layer are made of materials suitable for microwave heating. 35. A method of manufacturing brewing equipment, said method comprising the steps of: a container configured to store liquid for brewing and to dispense said liquid through at least one of the openings; Encapsulate the brewing substance with a heat-sensitive film layer; Covering the package with filter paper to form a subassembly; disposing the subassembly within the container at a location covering the at least one opening; and The container is configured to sit on top of a drinking container to allow liquid to drain from the at least one aperture into the drinking container. 36. The method of claim 35, comprising the step of securing said subassembly to said container. 37. The method of claim 35, comprising the steps of: configuring the bottom of the container to have a cavity formed to accept the subassembly; and disposing the subassembly in the cavity cavity. 38. The method according to claim 35, wherein said packaging step comprises: disposing the brewing substance on the first heat-sensitive film layer; applying a second heat-sensitive film layer over the brewing substance to form the top surface of the package; and The first and second layers are attached together along their outer boundaries to encapsulate the brewing substance within the first and second layers. 39. The method of claim 38, wherein the first and second heat-sensitive film layers encapsulating the brewing substance have different rupture temperatures. 40. The method of claim 35, wherein said covering step comprises: disposing first and second sheets of filter paper around said package; and The first and second sheets are sealed together at their outer boundaries to form the subassembly.

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