US20220227574A1

Movatterモバイル変換

Info

Publication number: US20220227574A1
Application number: US17/164,608
Authority: US
Inventors: Sung Oh
Original assignee: Individual
Current assignee: Individual
Priority date: 2020-01-30
Filing date: 2021-02-01
Publication date: 2022-07-21

Abstract

A single-serve beverage pod has a filter that is sealed to the rim of container where upon a predetermined force applied to the filter, the filter can separate from the rim to form a gap therebetween to drain the beverage. The rim also has a line of weakness which can also separate upon the application of the predetermined force to form the gap between the filer and the rim to drain the beverage. As such, the pod has two independent means of separating the filter from the rim to form the gap.

Description

RELATED APPLICATIONS

This application claims priority to a U.S. Provisional Application Ser. No. 62/968117, filed Jan. 30, 2020, entitled SINGLE-SERVE BEVERAGE POD DRAINING THE BEVERAGE WITH OR WITHOUT AN OUTLET PIERCING ELEMENT, which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION1. Field of the Invention

A single-serve beverage pod is configured to brew a beverage and drain the beverage therein via multiple outlets. In particular, the pod may be orientated to drain the beverage about the bottom side, sidewall, and/or the top side of the pod with or without an outlet piercing element piercing through the pod.

2. Background of the Invention

The following background discussion is not an admission that the matters discussed below are citable as prior art or common general knowledge. Brewing a hot beverage through single-serve pods are popular for their convenience and a variety of flavors of beverage which are offered. For instance, single-serve pods may be packed with premeasured coffee ground which can be inserted into a brewing mechanism to inject hot water into the pod to brew a cup of beverage. As of 2018, the market leader of single-serve pods in North America is Keurig Green Mountain, Inc.® that sells its single-serve platform under the Keurig® brand name, collectively referred to as Keurig®. Keurig® offers over 400 different variety of single-serve pods, also known as K-Cup® pods (hereinafter referred to as “K-Cup(s)” or “K-Cup pod(s)”). For instance, US. Patent Application Publication No. 2005/0051478 entitled BEVERAGE FILTER POD by Karanikos et al. (the “'51478 application”), which is hereby incorporated by reference in its entirety, generally describes the K-Cup pods offered in the market today. The '514778 application discloses a beverage filter cartridge having a cup like container where the interior is divided into two chambers by a cup-shaped filter element: a first chamber is located inside the filter and a second chamber is a space between the bottom of filter and the base of the container. The upper rim of the filter is joined at the upper opening of the container sidewall. The rim of the container is bonded with a lid to contain the coffee ground packed within the filter. The bottom of the filter is position above the bottom of the container such that the second chamber has enough space so that the tip of the bottom outlet needle does not pierce the bottom of the paper filter in order to prevent the paper filter from tearing open so that coffee ground do not escape from the filter during the brewing process.

In order to brew a beverage, a K-Cup pod is placed inside a brewer designed to work with the K-Cup pod. U.S. Pat. No. 7,347,138 (the '138 Patent”), which is hereby incorporated in its entirety, generally describes a brewer, offered by Keurig®, designed to work with K-Cup pods. The brewer includes a holder configured and dimensioned to receive a K-Cup pod generally in an upright position. The brewer has a cover that opens and closes, and underneath the cover is an inlet needle designed to pierce the lid of the K-Cup pod as the cover closes; and during the brewing process, heated water is injected into the first chamber via the inlet needle in order to brew a beverage as the water interact with the coffee ground packed within the filter. The beverage then flow pass the filter and into the second chamber but the coffee ground remain within the filter, The holder also has an outlet needle at the bottom to pierce the bottom of the container when the pod is pressed down into the holder. This allows the beverage within the second chamber to drain via the outlet needle.

Despite the popularity of the K-Cup pods, there are a number of disadvantages to brewing a cup of coffee with the K-Cup pod. First, while some K-Cup pods are recyclable, it is not easy to do so. For instance, after the K-Cup pod has been used to brew a beverage, the coffee ground within the spent pod hinders the container from being recycled. In this disclosure, a single-serve beverage pod that has been used to brew a beverage may be generally referred to as a “spent pod”. With the spent pod, a user may need to first remove the lid and discard the coffee ground within the filter in order to recycle the outer container with the filter still bonded to the container. In practice, many users may find that following these steps, in other words, removing the lid and then discarding the coffee ground to be cumbersome and messy. Accordingly, many users may not actually follow these steps to recycle the pods. Second, the K-Cup pods need to be pierced at the bottom of the container by an outlet needle in order to drain the beverage via the outlet needle. In some instances, the outlet needles can get clogged such that the beverage cannot be drained, which can cause the brewing mechanism to malfunction. Third, the same outlet needle is used to brew a variety of different flavor beverages, such as coffee, tea, and hot cocoa, but using the same outlet needle can contaminate the flavors among different flavored beverages. This can lead to unsatisfactory taste of the beverages. Accordingly, there still is a need for a K-Cup pod that can be recycled more conveniently, reduce the chances of the outlet needle getting clogged, and/or minimize the contamination of flavors due to using the same outlet needle for brewing different flavored pods.

SUMMARY OF THE INVENTION

One of the aspects of the invention is to provide a single-serve pod with a container having a base that extends upwardly to form a sidewall and extends outwardly to form a rim to define an opening, the rim having a line of weakness defining an outer section and an inner section of the rim where the inner section is juxtaposed to the sidewall; a filter having a filter base that extends upwardly to form a filter sidewall and extends outwardly to form an extension to define an opening adapted to receive beverage ingredient, where the opening of the container is adapted to receive the filter such that the extension is juxtaposed to the rim of the container; and an energy director between the rim of the container and the extension of the filter.

Another aspect of the invention is to provide a single-serve beverage pod that can be brewed in different orientations such as in a substantially upright position and a substantially horizontal position. When the pod is brewed in the substantially upright position, the formation of the beverage may be drained through a pierced hole formed within the base of the container but when the pod is brewed in the substantially horizontal position, the beverage can be drained through a gap formed between the rim and sidewall of the container and may pour directly into a mug to avoid contaminating the beverage. The container may be formed from a unitary part having a rim extending outwardly from a sidewall, and the rim may be separated from the sidewall via a line of weakness. The container may be also formed from separate parts peelably bonded together such that the rim part can be peeled away from the sidewall part to form a gap between the two parts to allow the beverage to drain via the gap.

In this regard, one of the aspects of the invention is directed to a beverage pod, comprising: a container having a first part peelably bonded to a second part along a bond area, the first part having a first sidewall that bends at a corner to form a first section and defining an opening around the first section, the second part having a base and a second sidewall that is outside and juxtaposed to the first sidewall to form a pathway between the first and second sidewalls and to have the first section extends outwardly from the second sidewall where the opening defines a top side of the container and the base defines a bottom side of the container, and the bond area is located near the top side of the container; a filter coupled to the first part such that the filter forms a pocket within the opening to receive a beverage substance within the pocket; and a lid coupled to the first section of the first part to enclose the opening and to hermetically seal the beverage substance within the container such when the beverage pod is brewed in a first orientation the base is pierced by an outlet piercing element to drain the beverage via the outlet piercing element, and when the beverage pod is brewed in a second orientation at least a portion of the bond area is separated to form a gap between the first and second parts by a separating element to allow beverage to flow along the pathway and drain via the gap.

Another aspect of the invention is directed to a beverage pod comprising: a container having: a first part having a first sidewall that bends at a corner to form a first section defining a first opening; a second part having a base that bends at a corner to form a second sidewall defining a second opening adapted to receive the first sidewall of the first part, the first part peelably bonded to the second part, and when the beverage pod is brewed in a first orientation the base is pierced by an outlet piercing element to form a pierced hole and when the beverage pod is brewed in a second orientation a portion of the first part is peeled away from the second part to form a gap; a filter bonded to the first part defining a first chamber and a second camber within the container, the first chamber defining a pocket adapted to pack a beverage substance such that formation of beverage within the first chamber passes through the filter and into the second chamber; and a lid enclosing the first chamber such that the lid and the container hermitically seal the beverage substance within the container, and during a brewing process, the beverage within the second chamber drains either through the pierced hole in the base or the gap formed between the first and second parts.

Yet another aspect of the invention is directed to a beverage pod beverage pod comprising: a container having: a first part having a first sidewall that bends at a corner to form a first section surrounding a first opening; a second part having a base and a second sidewall defining a second opening adapted to receive the first sidewall juxtaposed to the second sidewall, the first part peelably bonded to the second part, the second part formed from a pierceable material so that the base is pierceable when the beverage pod is brewed in a first orientation to form a pierced hole through the base, and a portion of the first part peeled away from the second part when the beverage pod is brewed in a second orientation to form a gap between the first and second parts; a filter bonded to the first part adjacent to the first opening defining a first chamber and a second camber within the container, the first chamber defining a pocket adapted to pack a beverage substance such that formation of beverage within the first chamber passes through the filter and into the second chamber; and a lid enclosing the first chamber such that the lid and the container hermitically seal the beverage substance within the container, wherein when the beverage pod is brewed in the first orientation, the pierced hole is first formed through the base during the brewing process and a gravitational force draws the beverage toward the base to drain the beverage through the pierced hole; and wherein when the beverage pod is brewed in the second orientation, the gap is first formed between the first and second part and the gravitational force draws the beverage toward the lid to drain the beverage through the gap.

Still another aspect of the invention is directed to a beverage pod a method of brewing a beverage with a pod including a filter within a container with a sidewall extending upwardly from a base and extending outwardly forming a rim, the filter having a pocket to receive beverage substance and bonding the filter between the rim and a lid to enclose the beverage substance within the pocket, the method comprising: injecting heated liquid through the lid of the pod to mix with beverage substance within the pocket to brew a beverage; draining the beverage formed within the pod through the base of the pod when the pod is in a first orientation such that the gravitational force directs the beverage to exit through the base; and draining the beverage formed within the pod through a gap formed between the rim and the sidewall when the pod is in a second orientation such that the gravitational force directs the beverage to exit via the gap.

Another aspect of the invention is directed to a beverage pod a beverage pod, comprising: a container having a sidewall extending upwardly from a base and extending outwardly from a bend location forming a rim having a first extension and a second extension that is slanted downward relative to the first extension, and the rim having a line of weakness around the rim and away from the bend location defining a proximal extension of the rim and a distal extension of the rim; a filter having a pocket with a ledge defining an opening to receive a beverage substance, and the ledge of the filter coupled to the first and second extensions of the rim; and a lid coupled to the ledge of the filter to enclose the opening and to seal the beverage substance within the container, wherein when a sufficient force is applied to a portion of the distal extension of the rim, the portion of the distal extension of the rim and the ledge of the filter separate from the proximal portion of the rim along a portion of the line of weakness to form a gap between the distal and proximal extensions.

Yet another aspect of the invention is directed to a beverage pod, comprising: a container having a first part peelabley coupled to a second part along a bond area, the first part having a first sidewall extending upwardly from a base, the second part having a second sidewall that bends at a corner to form a first section and defining an opening around the first section, the second sidewall juxtaposed to the first sidewall to form a pathway between the first and second sidewalls and to have the first section extend outwardly from the first sidewall such that an application of sufficient force upon the first section causes at least a portion of the second part to separate from the first part along a portion of the bond area to form a gap to allow formation of beverage to flow along the pathway and drain via the gap; a filter coupled to the second part such that the filter forms a pocket within the opening to receive a beverage substance within the pocket; and a lid coupled to the first section of the first part to enclose the opening and to hermetically seal the beverage substance within the container.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.

FIG. 1A shows a perspective view of a single-serve beverage pod.

FIG. 1B shows a cross-sectional view of the pod ofFIG. 1A along theline1B-1B.

FIG. 1C shows an enlarged view of the rim area of the pod as indicated by the encircled area marked1C.

FIGS. 2A through 2L show enlarged cross-sectional views of various alternative embodiments of the rim.

FIG. 3A show a cross-sectional view of the pod in a first orientation in reference to the gravitational force as indicated by a direction arrow g.

FIG. 3B show a cross-sectional view of the pod brewing a beverage in the first orientation and draining the beverage via an outlet needle.

FIG. 4 show a flow chart illustrating the steps that may be utilized to pre-weaken a line of weakness of the pod.

FIG. 5A shows a perspective view of a pod in a second orientation in reference to the gravitational force as indicated by a direction arrow g.

FIG. 5B is a cross-sectional view of the pod ofFIG. 5A along theline5B-5B illustrating flow of brewed beverage in the second orientation and draining the beverage without an outlet needle.

FIG. 6A shows a cross-sectional view of a pod placed within a brewing chamber orientated to brew and drain the beverage in a second orientation.

FIG. 6B shows a cross-sectional view of the pod ofFIG. 6A in an intermediate stage prior to piercing the lid with an inlet needle.

FIG. 6C shows a cross-sectional view of the pod in a second orientation for brewing and draining the beverage within the pod without an outlet needle.

FIG. 6D shows a cross-sectional view of the spent pod after the brewing process.

FIG. 7A illustrates a cross-sectional view of a pod in a second orientation ready to form a gap to drain the beverage.

FIG. 7B illustrates the pod in a second orientation having a gap to drain the beverage with minimal spattering of the beverage.

FIG. 8A illustrates a pod that supports the filter to enlarge a gap for draining the beverage.

FIG. 8B shows the pod ofFIG. 8A where a gap is formed to drain the beverage.

FIG. 9A illustrates another embodiment of a pod in a second orientation with a liner to isolate the inlet needle.

FIG. 9B shows the pod ofFIG. 9A with the liner isolating the inlet needle and a gap to drain the beverage.

FIG. 9C shows an expanded view of the pod ofFIG. 9A.

FIG. 9D shows another embodiment of a liner for the pod ofFIG. 9A.

FIG. 10A illustrates a pod having a liner incorporating a one-way valve.

FIG. 10B illustrates a pod without a filter.

FIG. 10C illustrate a pod having solid substances for brewing soup.

FIG. 11A shows a cross-sectional view of an alternative embodiment of a pod having an irregular shape sidewall.

FIG. 11B shows the pod ofFIG. 11A within a brewing chamber.

FIG. 11C shows the pod ofFIG. 11A with the sidewall that has been reshaped during the brewing process.

FIG. 12A shows a cross-sectional view of another embodiment of a pod having a shield to protect the filter.

FIG. 12B shows a perspective view of the shield.

FIG. 12C shows a pod having a shield with the filter attached to the shield.

FIG. 12D shows an alternative detail view of the shield attached to the container.

FIG. 12E shows another alternative view of the shield attached to the container.

FIG. 13A shows an alternative low-pressure pod in an upright expanded perspective view.

FIG. 13B shows an inverted perspective view ofFIG. 13A.

FIG. 13C shows an enlarge view of the holes in the base of the filter.

FIG. 14A shows an alternative high-pressure pod in an upright expanded perspective view.

FIG. 14B shows an inverted perspective view ofFIG. 14A.

FIG. 14C shows an enlarge view of the holes in the base of the high-pressure filter.

FIG. 15A shows enlarge view of extension of the filter and rim of the container.

FIG. 15B shows enlarge view of an energy director.

FIG. 15C shows enlarge view of an energy director in a different location.

FIG. 15D shows enlarge view of an energy director underneath the extension.

FIG. 16A shows an assembled pod ofFIG. 13A.

FIG. 16B shows an alternative pod from the pod illustrated inFIG. 13A.

FIGS. 17A throughFIG. 17D illustrate various stages of separating the extension from the rim to drain a beverage.

FIGS. 18A throughFIG. 18B illustrate alternative means of separating the extension from the rim to drain a beverage.

DETAILED DESCRIPTION OF THE INVENTION

The various aspects of the invention can be better understood with reference to the drawings and descriptions described below. The components in the figures, however, are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the various aspects of the invention. The claimed invention is not limited to apparatuses or methods having all of the features of any one apparatus or method described below or to features common to multiple or all of the apparatuses described below. The claimed invention may reside in a combination or sub-combination of the apparatus elements or method steps described below. It is possible that an apparatus or method described below is not an example of the claimed invention. In general, when the terms “may”, “is”, and “are” are used as a verb in the description corresponding to a particular subject matter, these terms are generally used in this disclosure as an expression of a possibility of such subject matter rather than as a limiting sense such as when the terms “shall” and “must” are used. For example, when the description states that the subject matter “may be” or “is” circular, this is one of many possibilities, such that the subject matter can also include an oval, square, regular, irregular, and any other shapes known to a person of ordinarily skilled in the art rather than being limited to the “circular” shape as described and/or illustrated in the corresponding referenced figure. In addition, when the term “may”, “is”, and “are” are used describe a relationship and/or an action, these terms are generally used in this disclosure as an expression of a possibility. For example, when the description states that a subject matter A “may be” or “is” adjacent to a subject matter B, this can be one of many possibilities including the possibility that the subject matter A is not adjacent to the subject matter B as it would be understood by a person of ordinarily skilled in the art.

Moreover, it is within the scope of the invention to combine the various embodiments disclosed relating to one or more particular drawing and their corresponding descriptions with one or more of other drawings and their corresponding descriptions disclosed herein and/or other references incorporated herein by reference where such a combination may be combined and practiced by one of ordinary skilled in the art. The phrase “single-serve beverage pod” in this disclosure generally refers to a single brewing process where a desired volume of beverage is brewed to serve one cup of beverage, however, it is within the scope of the invention to have a pod that packs sufficient beverage substance to brew multiple cups of beverage from a single brewing process or from multiple brewing processes. Also, the term “beverage substance” generally refers to the underline article when mixed with liquid such as water formulates a beverage such as coffee, tea, fruit drink, surgery drink such as punch, soda, cocoa, milk, soup, energy drink, liquid medicine, and the like. For instance, for coffee, the beverage substance may be coffee ground, instant powder coffee, and/or concentrated coffee in liquid form that can be diluted with water for consumption. For tea, the beverage substance may be tea ground, instant powder tea, and/or concentrated tea in liquid form that can be diluted with water for consumption. For baby milk, the beverage substance may be milk powder or concentrated milk liquid. For medicine such as for flu or cold, the beverage substance may be in the powder or liquid form which can be dissolved with predetermined portion of the heated water to brew a proper portion of the liquid medicine. In addition, the beverage substance may be provided in the form of pellets that are infused with desired flavors; and once the pellets are exposed to liquid such as water, the trapped flavors may be released by the pellets, which is then absorbed by the mixing liquid to formulate a beverage with the desired flavor. As such, the beverage substance may be in the form of ground, powder, liquid, pellets, and the like; and the beverage substance may be formulated from single or multiple ingredients. The same referenced numerals referred to in the drawings and descriptions generally correspond to same or similar parts throughout the disclosure.

FIG. 1A shows a perspective view of a single-servebeverage pod10 including acontainer12 and alid14 sized to enclose thecontainer12. In reference to the gravitational force as indicated by the direction arrow g, thecontainer12 may have a base16 and extending upwardly therefrom may be asidewall18, which may then extend laterally at abend location20 to form arim22. Thebase16 and thesidewall18 may be circular such that thebend location20 and therim22 may be correspondingly circular as well. The outer dimensions and configuration of thepod10 may vary depending on the application. The outer dimensions and configuration of thepod10, however, may include dimensions and configuration same or similar to that of K-Cup® pod found in the market today. Moreover, as discussed in more details below, a different pod having different size and configuration may be used along with thepod10, such as a second pod having a different height that is greater or smaller than the height of thepod10.

FIG. 1B shows a cross-sectional view of thepod10 along theline1B-1B shown inFIG. 1A; andFIG. 1C shows an enlarged portion of thepod10 as indicated by the encircled area marked1C where therim22 may have a slanted configuration that faces downwards toward thebase16. Thepod10 may include afilter24 forming a pocket generally defining afirst chamber28 within thecontainer12 configured to receive and hold thebeverage substance26. Thefilter24 may have a bottom30 with asidewall32 extending upwardly therefrom and extending outwardly from acorner34 to form aledge36 configured to nest over therim22 and seal to at least a portion of therim22. Theledge36 of the filter may be sealed to therim22 through a variety of methods known to one skilled in the art, such as being permanently or peelably bonded such that theledge36 of thefilter24 can be peeled away from therim22, if desired. Depending on the application, theledge36 may be bonded to therim22 through a variety of peelable bond known to one skilled in the art. The peelable bond may have sufficient strength to allow both bonded materials to remain bonded together during normal conditions of manufacturing, shipping, use, and brewing process while being sufficiently weak enough to allow one material to be peeled away from the opposite material by the application of sufficient force to separate the two materials. The sufficient force may be applied through the use of hand and/or via mechanical means within the brewing mechanism.

Thefilter24 may also define asecond chamber38 between thefilter24 and thesidewall18 and thebase16 of thecontainer12. Note that it is within the scope of the invention to have thesecond chamber38 be minimized such that the bottom30 of thefilter24 may contact thebase16 of thecontainer12. The filter may be formed within thecontainer12 such that apathway40 may be formed between thesidewall18 of thecontainer12 and thesidewall32 of thefiler24. Note that it is within the scope of the invention to have a portion of thefilter24 be in contact with thesidewall18 and/or thebase16. Thefilter24 may be formed from a variety of materials known to one skilled in the art such as paper filter, synthetic filtration material, moldable non-woven filtration material, biodegradable, compostable, and recyclable material. As an example, the non-woven filtration material may include a plurality of multi-component filaments that are bound or interlocked by non-woven manufacturing techniques (such as spunbond techniques) to form theledge36 extending outwardly around the circumference of thecorner34 of thefilter24. The basis weight forfilter24 adapted for filtering ingredients for preparing a single-serve beverage may be in the range from about 8 to about 400 grams per square meter (gsm), also from about 40 to about 150 gsm, and from about 60 to about 120 gsm. Depending on the brewing application, thefilter24 may be incorporated into thepod10 such as for brewing ground coffee and tea, however, there may be other brewing applications where the filter may not be needed such as when brewing instant coffee, power drinks like chocolate powder, milk powder, or any other soluble or insoluble ingredients, and etc.

Thepod10 may be enclosed by thelid14 to seal thefirst chamber28 of thefilter24 and/or therim22 of thecontainer12. In general, in reference to the orientation of thepod10 illustrated inFIG. 1A, thelid14 may represent the top side of thepod10, and the base16 may represent the bottom side of thepod10. The outer extension portion and/or intermediate portion of thelid14 may be coupled to theledge36 of the filter and/or extend over theledge36 and bond directly to therim22 as discussed in more detail below. Accordingly, depending the application, the diameter of thelid14 may be less, equal, or greater than the outer diameter of therim22 such that thelid14 may or may not overlap the entire outer circumference of therim22. Thelid14 may be formed from a variety of materials known to one skilled in the art such as aluminum, plastic liner, biodegradable, compostable, and recyclable material. In particular, thelid14 may be formed of a material that is resistant to tearing upon the application of a peel force. For instance, the lid may be formed from a multi-layered material that includes at least one layer that is resistant to tearing upon the application of a peel force. For example, thelid14 may have a minimum tensile strength of 3000 psi and a minimum elongation of 50%. Examples of materials that may be used to resistant tearing include polyethylene (PE), polyethylene terephthalate (PET) and polyamide PA6. A lid made of multi-la.yered material may include at least one layer formed of a continuous film of tear resistant material (laminated or extrusion coated) or a non-continuous film such as a non-woven polymer, mesh or perforated film. Examples of a multi-layered material forlid14 include (from outside layer to inside layer): PET/aluminum foil/PE, PET/EVOH/PE, PET/metalized PET/PE or PET/PE. Thelid14 may be formed from a flexible material such that if thelid14 is sized to overlap therim22, the lid may return to its original shape once the lid is free from the exterior restraints such as when a plurality of pods are packed within a box close to each other to minimize the size of the box. Alternatively, the pods may be made from biodegradable materials. For example, the pods may be made from biodegradable and/or compostable materials as disclosed in US Published Application No. 2014/0335236, entitled BIODEGRADABLE AND COMPOSTABLE SINGLE-SERVE BEVERAGE INGREDIENT PACKAGE, published Nov. 13, 2014; and also US Published Application No. 2013/0045308, entitled DISPOSABLE BIODEGRADABLE BEVERAGE PACKAGE, published Feb. 21, 2013, which are both hereby incorporated by reference in their entirety, and referred hereto as “biodegradable disclosures” below.

As illustrated inFIG. 1C, therim22 may have a line ofweakness42 around the circumference of therim22 such that therim22 may be separated from thesidewall18 when a sufficient force is applied to therim22 in a manner described below. Theledge36 offilter24 and thelid14 may be coupled to therim22 such that when a sufficient force is applied over and/or underneath therim22, therim22, theledge36, and thelid14 may separate from thesidewall18 along the line ofweakness42 in a manner described below. Therim22 may be slanted downward by an angle yr relative to a horizontal plane HP and the extension of therim22 from the line ofweakness42 may be ER. The angle ψ may vary from about 0° to about 90°, and from about 15° to about 60°, and in particular from about 30° to about 45°. The angle ψ may also be adjusted to allow thepod10 to work with cup holders in traditional brewing mechanisms that brews K-Cup pods where the bottom16 of the pod is pierced by an outlet needle or the like to drain the beverage via the outlet needle when the pod is generally brewed in an upright orientation. The length of the ER may vary from about 2.0 mm to about 10.0 mm, and from about 3.0 mm to about 8.0 mm, and in particular from about 4.0 mm to about 6.0 mm. Theledge36 of thefilter24 may be bonded to a portion of therim22 via afirst bond50, and theledge36 may be bonded to thelid14 via asecond bond52 such that theledge36 may be between the first and

second bonds

50 and52 in this embodiment, as discussed in more detail below.

The first and

second bonds

50 and52 may be bonded through a variety of methods known to one skilled in the art depending on the application. For instance, the first and

second bonds

50 and52 may have similar bonding strength or thefirst bond50 may be stronger than thesecond bond52, and vice versa. That is, the first and

second bonds

50 and52 may be individually and/or in combination permanent or peelable bond depending on the application. In reference to the embodiment illustrated inFIG. 1C, the first and second bonds may be permanent bonds such that they are not intended to be peeled off from their respective adhered members. The term “permanent” bond in this disclosure generally refers to relative strength of the bonds such that the permanent bond has stronger adherence characteristics than the peelable bond. The areas of the first and

second bonds

50 and52 may vary depending on the application and the desired strength of the bond. Also, the permanent and peelable bonding material may be a separate material from thefilter24 and thecontainer12 or it may be an integral part of the material (either a monolayer material or a layer of a multi-layered material) for one or both of thefilter24 andcontainer12. One example of afirst bond50 may be a heat sealable polymer such as polyethylene (PE) including low density PE, linear low density PE and high density PE. Thefirst bond50 may be provided as an inner sealing layer for thecontainer12 formed from a multi-layered material as discussed above or it may be provided as a separatefirst bond50. Other suitablefirst bond50 may include heat sealable materials such as polypropylene, lacquer, ethylene vinyl acetate (EVA), ethylene acrylates, polystyrene or combinations of the above. Adhesive materials (having comparable adhesion properties as described above to form a peelable bond) may be utilized for applications where a heat sealer is not desired or feasible. Suitablefirst bond50 materials that may be integral with thefilter24 include homocomponent materials (such as polyolefin, polyester, and polyamide) and multicomponent materials (such as polyester-polyolefin, polyamide-polyolefin and polyester-polyamide). Moreover, other bonding methods such as ultrasonic bonding method may be used.

FIGS. 2A through 2L show enlarged cross-sectional views of various alternative embodiments of therim22 of thepod10 and the manner in which theledge36 of thefilter24 and thelid14 may be bonded together to their respective adjacent layers and the locations of the line ofweakness42.FIG. 2A illustrates that thecontainer12 may have a first line ofweakness42 at thebend location20 on the exterior side of thecontainer12, and a second line ofweakness44 near thebend location20 on the corner where thesidewall18 bends to form therim22. In this embodiment, the first and

second bonds

50 and52 may be permanent bonds. That is, the bonding strengths between the two

bonds

50 and52 may be similar and resistant to separation from their respective bonding area under normal intended us. Moreover, thepathway40 may be formed between the two

sidewalls

18 and32.

FIG. 2B illustrates that thecontainer12 may have a first line ofweakness42 at thebend location20 on the exterior side of thecontainer12, and a second line ofweakness44 near thebend location20 but on theinner side12B of thecontainer12.FIG. 2C illustrates that therim22 may include afirst extension22B and asecond extension22C with a line ofweakness42 at thebend location20 on the exterior side of thecontainer12. Thefirst extension22B may extend outwardly in a lateral or horizontal manner; and this may providemore surface area46 on therim22, which in turn provides greater bonding area for a more secure bonding betweenledge36 and therim22. Thesecond extension22C may extend in an oblique or slanted manner relative from thefirst extension22B such that thesecond extension22C face towards thebase16 of thecontainer12. Alternately, the first and

second extensions

22B and22C may extend in a curve like manner where theedge48 of therim22 face downwards toward thebase16 of thecontainer12. Moreover, a portion of thesidewall32 of thefilter24 may contact thesidewall18 of the container thereby minimizing thepathway40 relative to thepathway40 shown inFIG. 2A.

FIG. 2D illustrate that the line ofweakness42 may be on theinner side12C of thecontainer12 adjacent to thebend location20.FIG. 2E illustrates that therim22 may have anextension54 adapted to more securely engage with a separatingelement216, as discussed in more detail below, to allow therim22 to separate from thesidewall18 of thecontainer12 along the line ofweakness42. In addition, theledge36 of thefilter24 and thelid14 may adhere to the taper portion of therim22 to increase the bonding surface area between theledge36 and therim22.FIG. 2F illustrates that the line ofweakness42 may be located at theinner side12C of thecontainer12 adjacent to thebend location20 with theextension54. Note that it is within the scope of the invention where thecontainer12 may have more than one line ofweaknesses42. For example, thecontainer12 have two lines ofweaknesses42 on its exterior and interior sides as illustrated inFIGS. 2E and 2F, respectively.

FIG. 2G illustrates that theledge36 of thefilter24 and thelid14 may be extended to encompass the first and

second extensions

22B and22C of therim22. Theledge36 of thefilter24 may be comprised of afirst extension36B and asecond extension36C which may be bonded to the first and

second extensions

22B and22C, respectively. The line ofweakness42 may be formed on theouter surface12B of therim22 about an extension distance R1 from thebend location20, which may be adjacent to theoblique location56 where thesecond extension22C bends from thefirst extension22B at the angle ψ as discussed above. With the line ofweakness42 located outside of the bodingarea46, thebonding area46 of the first and

second bonds

50 and52 may be sufficiently large to prevent the outside oxygen from entering the first and

second chambers

28 and32 of the pod. That is, even if the line ofweakness42 is unintentionally cut too deeply into therim22 such that outside oxygen may pass through the line ofweakness42, the sufficientlylarge bonding area46 prevents oxygen to entering the pod.

FIG. 2H illustrates that the line ofweakness42 may be formed at the extension distance R1 from the bend location as discussed above in reference toFIG. 2G, but on theouter side12C of therim22 adjacent to theoblique location56 where thesecond extension22C bends from thefirst extension22B.FIG. 2I illustrates that the first and

second extensions

36B and36C of theledge36 may be bonded to the first and

second extensions

22B and22C, respectively. However, thelid14 may be bonded to thefirst extension36B of theledge36 but not thesecond extension36C of theledge36. The line ofweakness42 may be formed on theouter surface12B of therim22 adjacent to thebend location20. In this example, thefirst bond50 between theledge36 and thefirst extension22B may be a peelable bond; and thesecond bond52 between theledge36 and thelid14 may be a permanent bond but a peelable bond may be suitable as well.

FIG. 2J illustrates that the line ofweakness42 may be formed on theinner side12C of therim22 adjacent to thebend location20.FIG. 2K illustrates that theledge36 of the filter may adhered to thefirst extension22B of therim22 while thelid14 may be extended to encompass the first and

second extensions

22B and22C of therim22. The line ofweakness42 may be formed at an extension distance R1 from thebend location20.FIG. 2L illustrates that the line ofweakness42 may be formed at thebend location20 on theexterior side12B of therim22. Note that it is within the scope of the invention to have a pod with thefirst extension22B but not thesecond extension22C such that theentire rim22 may be substantially horizontal. Moreover, as disclosed above, the line ofweakness42 may be located on the inner and/or outer sides of thecontainer12 and at different locations. In this regard, the die cuts and the bonds discussed in U.S. Pat. No. 5,178,293 is hereby incorporated by reference in its entirety. Moreover, a variety of combinations of line of weakness formed on the interior and/or exterior side of thecontainer12 may be utilized to ensure that thepod10 is properly sealed so that the beverage substance with in thepod10 may remain fresh as long as possible.

FIGS. 3A and 3B show a cross-sectional view of thepod10 with therim22 illustrated inFIG. 2G positioned within abrewing chamber60 in a first orientation in reference to the gravitational direction arrow g. Thebrewing chamber60 includes acover62 having aninlet piercing element64 such that the cover may close and open relative to aholder66 having anoutlet piercing element68 protruding from a bottom70 of the holder. Theholder66 has asidewall72 with alip74 defining anopening76 sized to receive thepod10 when thecover62 is fully open.

FIG. 3A shows thecover62 in a partially closed position relative to theholder66 such that theinlet piercing element64 has partially pierced through thelid14 but thetip68B of theoutlet piercing element68 abuts against thebase16 of thepod10 without piercing through the base16 until thecover62 fully closes. When thecover62 is in the partially closed position, therim22 may be between thecover62 and thelip74 such that the first and

second extensions

22B and22C, respectively, maintain their original shape as illustrated inFIG. 2G. In reference toFIG. 2G, the location of the line ofweakness42 and thesecond extension22C extending obliquely therefrom may be configured such that once thepod10 is within thebrewing chamber60, thelip74 may be aligned with at least a portion of thesecond extension22C; and thesecond extension22C does not interfere with the operation of thecover62.

FIG. 3B shows that as thecover62 fully closes relative to theholder66, thelip74 of theholder66 may abut against thesecond extension22C that causes thesecond extension22C to move upwards to be aligned laterally relative to thefirst extension22B. The upward movement of thesecond extension22C weakens the line ofweakness42 such that the line ofweakness42 may be pre-weakened once thecover62 fully closes relative to theholder66. Thereafter, the beverage may be brewed by injecting liquid into thepod10 through theinlet piercing element64 and the beverage may drain via theoutlet piercing element68 as indicted by thedirection arrows78. Thefirst bond50 between theledge36 of the filter and therim22 may be a peelable bond. Once the spentpod10 is removed from theholder66, the line ofweakness42 has been pre-weakened by thebrewing chamber60 such that thesecond extension22C may be separated from thefirst extension22B along the line ofweakness42 more readily by the user. That is, the spentpod10 may be removed from thebrewing mechanism40 by the user; and if the user desires to recycle thepod10, the user may grab and pull away any portion of thesecond extension22C to cause thesecond extension22C to separate from thefirst extension22B along the pre-weakened line ofweakness42, and cause theledge36 of the filter to peel away from thefirst extension22B due to the peelable bond used between theledge36 and therim22. And as the user continues to pull on thesecond extension22C, the rest of thesecond extension22C, thefilter24, and thelid14 may separate from the rest of thefirst extension22B along the pre-weakened line ofweakness42. Even with thesecond extension22C separated from thecontainer12, the bulk of thecontainer12, which includes thefirst extension22B, may be recycled.

Placing thepod10 in a brewing position may also be referred to as a first orientation where thepod10 is positioned relative to the gravitational direction arrow g such that thedirection arrow78 of the beverage generally flows towards thebase16 of thecontainer12 to allow the beverage to drain via theoutlet piercing element68. That is, the first orientation of thepod10 may include positioning thepod10 in a slanted position relative to the gravitational direction arrow g, as long as the beverage is able to flow towards the base16 to be drained through a variety of methods known to one skilled in the art. Moreover, while the above description generally relates to the embodiment disclosed in reference toFIG. 2G working with thebrewing chamber60, other embodiments of the pod disclosed in references toFIGS. 2A through 2L may work with thebrewing chamber60 as well.

FIG. 4 show aflow chart90 illustrating the steps that may be utilized to pre-weaken the line ofweakness42 of thepod10. Instep92, apod10 may be provided for brewing a beverage having arim22 that has a line ofweakness42 around the circumference of therim22 where at least a portion of therim22 extends obliquely22C from the line ofweakness42 and towards thebase16 of thecontainer12. Note that the line ofweakness42 need not go around the entire circumference of therim22. Instep94, theholder66 may receive thepod10 when thecover62 is in an open position. Instep96, the line ofweakness42 may be weakened as thecover62 closes relative to theholder66 as thelip74 of theholder66 abuts against thesecond extension22C portion of therim22, which causes thesecond extension22C to move upwards to be aligned laterally relative to thefirst extension22B. The upward movement of thesecond extension22C weakens the line ofweakness42 such that the line ofweakness42 may be pre-weakened once thecover62 fully closes relative to theholder66. Accordingly, once the line ofweakness42 has been pre-weakened, it may be easier for a user to peel away thesecond extension portion22C,lid14, and filter24 from the rest of thecontainer12 for recycling purpose.

FIG. 5A shows a perspective view of thepod10 illustrating that thepod10 may brew a beverage in a second orientation that may be in a substantially horizontal position relative to the gravitational direction arrow g. In this example, therim22 of thepod10 may be the embodiment illustrated inFIG. 2C with thesecond extension22C extending out from underneath thelid14. In the second orientation, aninlet piercing element100 may pierce thelid14 at a vertical distance from thecenter102 of thelid14 to allow the portion of the beverage substance that is above the center of axis of thepod10 to be wetted first. However, it is within the scope of the invention to have theinlet piercing element100 pierce at or near thecenter102 of thelid14. As discussed in more details below, apeelable portion104 of therim22 that is below theinlet piercing element100 or at about six O'clock position may be separated from thesidewall18 along the line ofweakness42. Note that thepeelable portion104 may be anywhere around therim22 depending on the orientation of thepod10 relative to theinlet piercing element100. As thepeelable portion104 of therim22 is separated, the corresponding portion of thelid14 and thefilter24 may be separated from thesidewall18 as well leaving agap106 between thefilter24 and thesidewall18 of thecontainer12. The circumference around thesidewall18 in which thepeelable portion104 is separated or the arc of the peelable portion may be defined as an arc angle β in reference to thecenter102 of thelid14. The arc angle β may be from about 15° to about 180°, and from about 30° to about 120°, and also from about 45° to about 90°.

FIG. 5B is a cross-sectional view of thepod10 along theline5B-5B ofFIG. 5A to illustrate thegap106 formed between thefilter24 and thesidewall18 as theportion104 is separated along the line ofweakness42. In particular, with reference toFIG. 1B discussed above, thefilter24 may be molded such thefilter24 may substantially maintain its shape during the brewing process so that thepathway40 between thesidewall18 of the container and thesidewall32 of the filter may be substantially maintained to allow the beverage to flow along thepathway40 and drain from thegap106. During the brewing process,heated water108 may be provided to theinlet piercing element100 to inject theheater water108 into thepod10, which interact with thebeverage substance26 within thefilter24 such that the heated water washes away thebeverage112 from thebeverage substance26 as indicated by thedirection arrows112. The formation of thegap106 between thepeelable portion104 of therim22, which is attached to theledge36 of the filter, and thesidewall18 in the second orientation of thepod10 allows the beverage110 within thecontainer12 to drain via thegap106 as illustrated by thedirection arrows112. Thecontainer12 may be formed from a malleable material when exposed to elevated temperature such that during the brewing process, the separated portion of thesidewall18 may expand thereby enlarging thegap106 due to the rise in the temperature and pressure within thepod10 from the heated water injected into thepod10 under pressure. In this regard, thepod10 and in particular thecontainer12 may be more conducive to being formed from biodegradable materials. In general, biodegradable materials are made from plant-base materials like corn such that biodegradable material may be more malleable than the conventional multilayered material discussed above to form thecontainer12 due to the elevated heat and pressure within thecontainer12 during the brewing process.

The beverage may flow along the path within thepod10 as generally indicated by thedirection arrows112. In general, theinlet piercing element100 may pierce thelid14 at a vertical distance from thecenter102 of thelid14 to allow the portion of the beverage substance that is above the center of axis of thepod10 to be wetted first. That is, theinlet piercing element100 may be position to inject heated water into thepod10 to take account of the capillary action of the beverage substance and gravitational force when thepod10 is used in the second orientation so that the heated water may be distributed within thefilter24 to washes away the flavor from the beverage substance evenly. Such even distribution ofheated water108 within thefilter24 may allow the beverage substance to be washed more evenly which may result in a smoother tasting beverage. As the beverage exit thefilter24, the gravitational force directs the beverage downwards toward the separated portion of thesidewall18 to allow the beverage to flow along thepathway40 and exit along thegap106.

As the beverage drains through thegap106, thesecond extension22C of therim22 may extend in a downwardly direction to act, in part, as a funnel to direct the beverage into a mug (not shown) as indicated by thedirection arrows112. Thesecond extension22C may minimize the beverage from spattering to drain the beverage in a clean manner. In addition, thepod10 may drain the beverage without the need for an outlet piercing member thereby eliminating the possibility of contamination due to using the same outlet piercing member for subsequent pods with different flavored beverages, such as coffee and tea. Moreover, in some instances, some particles of thebeverage substance26 may escape from the filter and clog the outlet piercing element, which can cause the brewing mechanism to malfunction. And once thepod10 has been brewed, theportion104 of therim22 is pre-peeled from thesidewall18 such that it may be easier for the user to completely separate the lid and the filter from the rest of thecontainer12 by grabbing onto thepeelable portion104 to fully peel away thecontainer12 from the lid and filter to recycle the container. That is, many recycling facilities in the U.S. may not be able to recycle the container unless the container has been separated from the lid and filter due to the beverage substance contained therein. Thecontainer12 may be separated from the lid and filter after the spentpod10 has been removed from the brewing mechanism or while the spentpod10 is still held within the brewing mechanism. Note that it is within the scope of the invention to have the beverage within the container drain via thegap106 and/or an opening formed with an outlet piercing member along the base16 or on thesidewall18 to allow the beverage to drain when thepod10 is in the second orientation. In addition, the beverage may exist thegap106 and pour into a funnel (not shown) which then directs the beverage to pour into a mug.

FIGS. 6A, 6B, and 6C show a cross-sectional view of abrewing chamber200 capable of peeling theportion104 of thepod10 having the rim embodiment illustrated inFIG. 2C to form thegap106. Thebrewing chamber200 may include afirst potion202 and asecond portion204. Thefirst portion202 may include acap206 with theinlet piercing element100. Thesecond portion204 may include aholder208 with asidewall210 to form anopening212 with adepression214 therein such that thepod10 may be placed into theopening212 and into thedepression214. Theholder208 may also have aseparating element216 configured to support and abut the underside of therim22 associated with thepeelable portion104 of thepod10 such that thepod10 may not fully insert into thedepression214 when a user places thepod10 into theholder208. That is, as thepod10 is placed into theopening212 of theholder208, the underside of thesecond extension22C may engage with the separatingelement216 and guide thepod10 into a proper position relative to the separatingelement216 such that the separatingelement216 may abut against the underside of thefirst extension22B adjacent to the line ofweakness42. In particular, the underside of thesecond extension22C may have a concave like surface such that as the user places thepod10 into theopening212 of the holder, the concave surface of thesecond extension22C may assist the user in placing thepod10 in a consistent manner to ensure that the separatingelement216 is properly aligned adjacent to the line ofweakness42 to separate thepeelable portion104 from thesidewall18 of thecontainer12.

The first and

second portions

202 and204 may be mechanically engaged such that theopening212 of theholder208 is accessible to the user to allow the user to place thepod10 into theopening212 as illustrated inFIG. 6A. In addition, although not necessary, theholder208 may be orientated at an angle θ relative to ahorizontal plan218 so that theopening212 may face a user to allow the user easier access to theopening212 to place thepod10 into theholder208. However, it is within the scope of the invention to have theholder208 be movable or non-movable and at a variety of orientations as long as the angle θ is such that the gravitation force, as indicated by the direction arrow g, and the pressure within the pod allows the beverage formed within thepod10 to drain in a manner described above in reference toFIG. 5B. Moreover, whileFIG. 6A shows theholder208 orientated to have an angle θ, it is within the scope of the invention to have the angle θ be zero or even tilted in a negative orientation. Furthermore, some cross-sectional views of the pods may not show the beverage substance within the first chamber or filter in order to better indicate certain reference numerals in the drawings; however, such cross-sectional views of the pods should be viewed as including a beverage substance within the filter or within thecontainer12 in those applications when the filter may not needed such as when concentrated powder is used to brew coffee, tea, and hot chocolate cocoa.

FIG. 6B illustrates thefirst portion202 partially engaged with thesecond portion204. The first and

second portions

202 and204 may be mechanically engaged with an actuator (not shown) such as a handle (not shown) so that when the actuator is activated by a user, for example, the first and

second portions

202 and204 may move in a predetermined manner relative to each other so that theinlet piercing member100 may pierce thelid14, and thesecond portion204 may move to a more horizontal position, as indicated by thedirection arrow220, such that the angle θ may be from about −20° to about +20°, and preferably from about −5° to about +5°. In this regard, the handle mechanism, brewing mechanism, and its corresponding pod disclosed in U.S. Pat. No. 9,549,636 entitled BEVERAGE FORMING DEVICE WITH BEVERAGE OUTLET CONTROL, which is hereby incorporated by reference in its entirety, may be utilized to brew a beverage in a more horizontal position. Again, the angle θ may vary as long as the gravitation force and the pressure within the pod allows the beverage formed within thepod10 to drain in a manner described above in reference toFIG. 5B. Although not necessary, thefirst portion202 may orient thecap206 so that theinlet piercing element100 penetrates thelid14 in a substantially perpendicular manner, as indicated by thedirection arrow222, to minimize the pierced opening area226 (seeFIG. 6C) on thelid14 to minimize the chance that beverage within thepod10 may leak out from the opening formed by theinlet piercing element100.

FIG. 6C illustrates thefirst portion202 moving towards thesecond portion204, as indicated by thedirection arrow226, to fully engage with thesecond portion204 as the actuator is further activated relative to theFIG. 6B, but prior to the brewing process. Alternatively, thesecond portion204 may move towards the first portion201 as indicated by the direction arrow228, or in some combination where both of the first and

section portions

202 and204 are moved toward each other simultaneously. As thefirst portion202 further engages with thesecond portion204, the angle θ may further reduce relative to the position illustrated inFIG. 6B or the angle θ may remain the same. Moreover, as thefirst portion202 moves towards thesecond portion204, theinlet piercing element100 pierces through thelid14, and thecap206 pushes on theupper portion132 of thelid14 and therim22 to further push thepod10 into theholder208. The separatingelement216, however, substantially prevents thepeelable portion104 along with thecorresponding rim22 from being inserted into theholder208 such that thepeelable portion104 detaches from thesidewall18 along the corresponding portion of the line ofweakness42, thereby forming thegap106 between the rim22 (which may be attached to the filter24) and thesidewall18 to allow the beverage to drain along thegap106. By way of analogy, if thelid14 is viewed as a face on a clock, then thecap206 may be configured so that thepeelable portion104 of therim22 may be from about 3 O'clock to about 9 O'clock, alternatively from about 4 O'clock to about 8 O'clock, and also from about 5 O'clock to about 7 O'clock. Note the portion of therim22 that is peeled from thesidewall18 is not limited to any particular circumference as long as there is asufficient gap106 to allow the beverage to pass along the gap. During the brewing process, a desired beverage may be brewed by injecting heated liquid into theinlet piercing member100 and draining the beverage in a manner described in reference toFIG. 5B.

FIG. 6D shows the first and

second portions

202 and204 in their respective positions as illustrated inFIG. 6A with the spent thepod10. In other words, once thepod10 is in a brewing position as described in reference toFIG. 6C, heated water may be injected into thepod10 in a manner described above in reference toFIG. 5B. The spentpod10 has anopening212 formed by theinlet piercing element100 with thepeelable portion104 already separated from thesidewall18. During the brewing process, thesidewall18 that has been separated from thepeelable portion104 may expand, due to the heat and pressure within thepod10 such that thelip230 of thesidewall18 may have a spout like configuration to allow the beverage to drain more smoothly from thegap106. To remove the spentpod10, a user may grab thepre-peelable portion104 along with therim22, and lift thepre-peelable portion104 attached to thefilter24. As thepre-peelable portion104 is lifted, the expandedlip230 may abut against thetip232 of the separatingelement216 thereby preventing thecontainer12 from egressing thedepression214 of theholder208. And as the user continues to lift thepre-peelable portion104, the rest oflid14 and thefilter24 holding thebeverage substance26 may be peeled away from thecontainer12 along the line ofweakness42 while thecontainer12 remains held within theholder208. Thereafter, the user may remove thecontainer12 from theholder208 to be discarded or recycled.

FIG. 7A illustrates a cross-sectional view of thepod10 with the detail view of therim22 illustrated inFIG. 2G placed into thesecond portion204. As thepod10 is placed into theopening212 of theholder208, the underside of thesecond extension22C with its concave like inner surface may engage with the separatingelement216B and guide thepod10 into a proper position so that the separatingelement216B is properly aligned against the underside of thesecond extension22C and adjacent to the line ofweakness42. In addition, thesidewall210 of theholder208 may have alip234 configured to be aligned with thesecond extension22C such that the line ofweakness42 may be pre-weakened in a manner discussed above in reference toFIGS. 3A and 3B.

FIG. 7B illustrates that as thefirst portion202 and thesecond portion204 engage relative to each other, the separatingelement216B separates thesecond extension22C from thefirst extension22B along the line ofweakness42 such that thesecond extension22C of therim22 may be utilized to direct the flow of beverage draining from thegap106. That is, thesecond extension22C of therim22 may be substantially vertical or generally along the direction of the gravitational force g or along any other orientation to facilitate smooth flow of beverage exiting from thepod10. Thefirst extension22B may remain attached to thesidewall18 such that thefirst extension22B may act as a spout to facilitate draining the beverage smoothly along thefirst extension22B. This may allow the first and

second extensions

22B and22C to work together to act as a spout and funnel, respectively, to direct the flow of beverage draining from thegap106 to minimize splattering of the beverage. Note that the shape of thefirst extension22B and the underside of thesecond extension22C and the angle ψ (seeFIG. 7A) may be varied to control the manner in which the beverage within thepod10 drains from thegap106 and pours downward towards the mug below thebrewing chamber200. In addition, as discussed in reference toFIG. 3B, as thefirst portion202 fully closes relative to thesecond portion204, thelip234 of theholder208 abuts against thesecond extension22C, which may cause thesecond extension22C to move upwards to pre-weaken the line ofweakness42.

FIGS. 7A and 7B illustrate that thepod10 with therim22 illustrated inFIG. 2G is capable of brewing in the first and second orientations along with other embodiments of thepod10 illustrated inFIG. 2A through 2L. Moreover, other embodiments disclosed herein may be combined with any one or more alternative embodiments of therim22 to brew in the first and second orientations as well. For example, therim22 illustrated inFIG. 2G may have theledge36 of thefilter24 extend to thefirst extension22B but not to thesecond extension22C as illustrated inFIG. 2L. Also, therim22 illustrated inFIG. 2G may have theledge36 of thefilter24 not bonded to thefirst extension22B of therim22 but theledge36 may be bonded to thesecond extension22C. As another example, therim22 illustrated inFIG. 2G may have theledge36 of thefilter24 bonded along the first and

second extensions

22B and22C except near theoblique location56 where the line ofweakness42 may be formed such that there are two distinct peelable bonded areas between theledge36 of the filter and therim22, a first bonded area between theledge36 and thefirst extension22B, and a second bonded area between theledge36 and thesecond extension22C. Still further, therim22 illustrated inFIG. 2L may have theledge36 of thefilter24 not bonded to thefirst extension22B but have thelid14 bonded to theledge20 and thesecond extension22C. As such, it is within the scope of the invention to combine various disclosed embodiments, such as the line of weaknesses, bonding between two substrates, containers, rims, lids, ledges, and/or filters disclosed in the specification with one or more of other embodiments.

FIGS. 8A and 8B illustrate another embodiment of a separatingelement216C that may move as indicated by thedouble direction arrows236 between a retracted position236A as shown inFIG. 8A and an extended position236B as shown inFIG. 8B relative to theholder208.FIG. 8A shows that in the retracted positon236A, the separatingelement216C may be flush with theopening212 formed by thesidewall210 to allow thepod10 to fully insert into thedepression214 of theholder208. Thebase16 of thecontainer12 may have acavity120 at about its center. The bottom30 of thefilter24 may be sealed to thetip122 of thecavity120 to support thefilter24 when thepod10 is used in the second orientation so that thepathway40 between thesidewall32 of thefilter24 and thesidewall18 of thecontainer12 may be substantially maintained. Note that thepod10 with thecavity120 formed on the center of the base16 may be operable with thebrewing chamber60 described in reference toFIGS. 3A and 3B since theoutlet piercing member46 pierces thebase16 near the edge where thesidewall18 extends upwards rather than at the center of thebase16. Thecavity120 formed within thebase16 may have a variety of configurations such as semi-spherical, pyramid, rectangular, and etc.

FIG. 8B shows that as thefirst portion202 slides towards thesecond portion204, as indicated by thedirection arrow226, the separatingelement216C may also slide out relative to theholder208 towards the extended position236B. The combined motion of thefirst portion202 and the separatingelement216C separates thepeelable portion104 fromsidewall18 to form thegap106. In addition, thetip122 of thecavity120 supports the bottom30 of thefilter24 such that as thepeelable portion104 begins to separate from thesidewall18 of the container, thesidewall32 of thefilter24 adjacent to thegap106 extends and away from thesidewall18 to substantially maintain thepathway40 and thegap106 to provide a path for the beverage110 within thepod10 to drain. The first and

second portions

202 and204 and the separatingelement216C may be mechanically interlinked such that actuation of an actuator may cause the first and

second portions

202 and204 and the separatingelement216C to move in a manner described above. Conversely, once the brewing process is finish, the separatingelement216C may move back to the retracted position236A shown inFIG. 8A such that it may be easier for a user to remove thepod10. Alternatively, the bottom30 of thefilter24 may be deep enough to reach thebase16 of thecontainer12 having a flat bottom and a portion of the bottom30 of thedeep filter24 may be sealed to thebase16.

Another alternative mechanical or motorized arrangement may have the movement of the actuator causes the first and second portions to fully enclose relative to each other and have the separatingelement216C move from the retracted position236A to the extended position236B to peel thepeelable portion104 and then return to the retracted position236A so that the separatingelement216C does not interfere with the flow of beverage from thegap106. Moreover, with the separatingelement216C in the retracted position during the brewing process, the beverage draining from thegap106 may not be contaminated by the separatingelement216C since the separatingelement216C remains substantially clean and does not come into contact with the beverage.Other separating elements216A and216B may also be mechanically linked or motorized to isolate the separating element away from the path of the beverage draining from thegap106 and into the mug to substantially prevent the separating element from contaminating the beverage during the brewing process.

FIGS. 9A, 9B, 9C, and 9D illustrate another aspect of a modifiedpod10 capable of peeling theportion104 of thelid14 to form agap106 that is larger than thegap106 illustrated inFIG. 6C. In this embodiment, thepod10 may include aliner134 placed between thelid14 and theledge36 of thefilter24, which is supported by therim22 of thecontainer12. Theliner134 may be formed from a material that is permeable to air and water but substantially impermeable to beverage substance. Moreover, as illustrated inFIG. 9B, theliner134 may be substantially resistant to being punctured by thetip114 of theinlet piercing element100 such that the liner may have sufficient tensile strength so that theinlet piercing element100 may pierce through thelid14, but thetip114 may push theliner134 out without tearing through theliner134. As such, theliner134 may substantially isolate theinlet piercing element100 to minimize contamination of theinlet piercing element100 such that the sameinlet piercing element100 may be used to inject water into different flavored of pods such as coffee, tea, soup and milk, without the flavor from the spent pod contaminating the flavor of the subsequent pods having a different flavor. In addition, theliner134 may also prevent theinlet piercing element100 from getting clogged by the small particles of thebeverage substance26 to ensure proper performance of the brewing mechanism. Theliner134 may be also formed from water filtering material so that the water injected into the pod by theinlet piercing element100 may be purified to improve the quality of the beverage.

FIG. 9A also shows that the separatingelement216 may move between a retractedposition244 and anextended position246 about ahinge248 as indicated by thedirection arrow255. For instance, thehinge248 may be spring loaded to be biased towards the retractedposition244. However, when sufficient force is applied to the separatingelement216, the separatingelement216 may move in a counter-clockwise direction towards theextended position246. For example, as the spentpod10 is removed from thesecond portion204, the separatingelement216 may move towards theextended position246 so that thelip230 of thesidewall18 may not interfere with the tip of the separatingelement216.

FIG. 9B shows that as thefirst portion202 slides towards thesecond portion204, as indicated by thedirection arrow226, and as discussed above in reference toFIG. 6C, theinlet piercing element100 may pierce through thelid14, but theliner134 may resist being pierced and stretched by theinlet piercing element100 such that theliner134 separates from thelid14 thereby forming athird chamber136 between thelid14 and theliner134. Thethird chamber136 may have a cone like configuration extending across the diameter of therim22, for example, with theapex area138 being the area where thetip114 of theinlet piercing element100 pushes on theliner134. In addition, as the separatingelement216 detaches thepeelable portion104 of thelid14 from thesidewall18, the tensile strength of theliner134 may substantially prevent theliner134 from stretching such that the radius R may be substantially maintained between theapex area138 and theseparation location140 along the line ofweakness42. And as theseparation location140 moves in a clock-wise direction, theseparation location140 may also move in an upwardly direction towards theinlet piercing element100 such that the size of thegap106 between thesidewall32 of thefilter24 and thesidewall18 of thecontainer12 may be greater than thegap106 illustrated inFIG. 6C. For example, theenlarged gap106 may be illustrated inFIG. 9B by theseparation location140 being farther away from the tip of the separatingelement216 and closer to thetip114 of theinlet piercing element100 compared to the location of the separation location illustrated inFIG. 6C. Theenlarged gap106 may allow the beverage within thecontainer12 to flow at a slower rate to allow the beverage to flow more smoothly.

FIG. 9C shows an expanded view of thepod10 including theliner134 located between thelid14 and theledge36 of thefilter24, which is supported by therim22. The outer edges of thelid14 and theliner134, and the outer edges of theliner134 and theledge36 of the filter may be sealed together through a variety of methods known to one skilled in the art. For instance, thelid14 and theliner134 may be sealed together via peelable or more permanent bond; and theliner134 and theledge36 may be sealed together via peelable or more permanent bond. Theliner134 may also have anenforcement patch142 having a circular configuration with anopening144 at the center. Thepatch142 may further strengthen theliner134 to prevent theliner134 from stretching and tearing. In addition, the circular configuration of thepatch142 may allow thepod10 to be placed into thesecond portion204 in any orientation and still have thepatch142 abut thetip114 of theinlet piercing element100 when the piercingelement100 is configured to pierce thelid14 off centered as illustrated inFIG. 5A.

FIG. 9D shows a perspective view of another alternative embodiment of theliner134A which may be formed from impermeable material that resists being pierced and stretched by theinlet piercing element100. Theliner134A may also have acenter patch142A with a one-way valve146 that allows the water injected into thethird chamber136 by theinlet piercing element100 to exit thethird chamber136 via the one-way valve146 and into thefirst chamber28 but prevents the beverage formed within thefirst chamber28 from entering thethird chamber136. That is, theliner134A may be formed from an impermeable material to liquid such that the liquid and/or beverage may not pass through theliner134A other than via the one-way valve146 from thethird chamber136 to the first and

second chambers

28 and32 but prevents the liquid beverage from passing through theliner134A and the one-way valve146 from the first and/or

second chambers

28 and32 to thethird chamber136. This allows theinlet piercing element100 to be isolated from the beverage formation within thefirst chamber28 to prevent theinlet piercing element100 from getting contaminated; and when thepod10 is brewed in the second orientation as discussed above, the beverage within thepod10 may be drained without the need for an outlet piercing element so that cross-contamination from brewing different flavor beverages from different pods may be eliminated or at least minimized. Alternatively, when theinlet piercing element100 is configured to pierce thelid14 about its center, thepatch142 that is permeable to liquid may be adhered to theliner134 about its center to abut the piercingelement100 to further protect the permeable liner from piercing by the inlet piercing element.

FIG. 10A illustrates thepod10 having theliner134A with thepatch142 incorporating the one-way valve146 directing the flow ofliquid108 as indicated by thedirection arrow148. Thepod10 may be also packed with the beverage substance in the form of a predetermined portion ofpellets150 infused with desired flavors and or ingredients within thefirst chamber28 or thefilter24. As theinlet piercing element100 injects water into thethird chamber136, the liquid may exit through the one-way valve146 as indicated by thedirection arrow148 from thethird chamber136 to thefirst chamber28 and mix with thepellets150 within thefirst chamber28 to formulate a beverage. The beverage may then pass through thefilter24 and gather in thesecond chamber38 and drain via thegap106 as indicated by thedirection arrows148. Thepellets150 may be contained within thefilter24 during the brewing process and the beverage may be prevented from entering thethird chamber136. Thepellets150 may be infused with a variety of flavors such as sweet, fruity, and acidic flavors. Thepellets150 may also be infused with carbon dioxide (CO₂) to carbonate the beverage. In such instances, the liquid may be provided at a cooler temperature from about 5° C. to about 20° C., which allows the beverage to retain the carbon dioxide infusion for a longer period of time.

FIG. 10B illustrates that thepod10 may not incorporate afilter24. In this embodiment, thebeverage substance26 may be contained within apouch152 that may be formed from an edible film that dissolves when the film comes into contact with water. As an example, thepouch152 may be made from an edible film as disclosed in the US Published Application No. 2014/0199460, entitled EDIBLE WATER-SOLUBLE FILM, published Jul. 17, 2014, which is hereby incorporated by reference in its entirety. Note that other edible films or pouches known to one skilled in the art may be utilized. Thebeverage substance26 contained within thepouch152 may be in the form of powder or liquid. As illustrated inFIG. 10B, thebeverage substance26 may be wrapped within thepouch152 to prevent thebeverage substance26 from draining or pouring out of thegap106 until theinlet piercing element100 injects water into thethird chamber136 and then into thesecond chamber38, which in this embodiment in the absence of thefilter24 is the space between theliner134A and thecontainer12. Once liquid passes into thesecond chamber38 via the one-way valve146, thepouch152 may come into contact with the water and may begin to dissolve such that most, if not all, of thebeverage substance26 may remain within thepod10 to be mixed with the liquid injected into thesecond chamber38. This may allow theentire beverage substance26 more time to mix with the liquid within thesecond chamber38 to dissolve more completely with the liquid to improve the quality of the beverage formation. In addition, thepouch152 may be encased within thepod10 so that thepouch152 may be protected from the outside elements to prevent premature release of thebeverage substance26 contained within thepouch152. That is, thelid14 and thecontainer12 may be made from multiple layers including a barrier layer to protect the contents inside thepod10 from the outside elements such as oxygen and moisture, as discussed above, and thecontainer12 may also act as a protective shell to protect thepouch152 from being punctured by a foreign object. This allows thepouch152 to be protected by thepod10 during the packaging process, shipping, handling, and storing until the brewing process where thepouch152 releases its beverage substance after getting wet with liquid.

Thepod10 may also include asupport member154 configured in a circular disk like shape with a plurality ofholes126 therein to allow the beverage to pass therethrough. Thesupport member154 may be provided between thepouch152 and thebase16 of thecontainer12. When thepod10 is utilized in a first orientation, as illustrated inFIGS. 3A and 3B above, thesupport member154 may protect thepouch152 from tearing by theoutlet piercing element68. That is, as thepod10 is fully inserted into thecup holder66 in the first orientation, theoutlet piercing element68 may pierce through thebase16 of thecontainer12 and then abut against thesupport member154. This may prevent the tip of theoutlet piercing element68 from coming into contact with thepouch152, thereby preventing thefilm152 from potentially tearing and prematurely releasing itsbeverage substance26 content therein and draining via theoutlet piercing element68 before the heated water is injected into thethird chamber136 by theinlet piercing element100. Accordingly, thepod10 incorporating thepouch152 may be brewed in the first and second orientations, or may orientation therebetween the first and second orientation such that thebeverage substance26 may be retained within thecontainer12 to mix properly with liquid such as heated or cool water prior to draining via thegap106 or theoutlet piercing element68. Note that when thepod10 is brewed in the second orientation, however, the beverage formed within thepod10 may be drained via thegap106 so that the cross-contamination between different flavored pods may be eliminated or at least minimized since the beverage does not come into contact with an outlet piercing element.

Thefilm152 of thepouch152 may be edible to consumers, which allows thepouch152 to pack a variety of different beverages such as concentrated medicines for cold, flue, pain relief, sleeping aid, vitamin supplement, herbal, dietary supplement, and the like. Theconcentrated beverage substance26 packed within thepouch152 may also include baby milk, soup broth, energy drinks, coffee, cold brew coffee, concentrated tea, cocoa, fruit, punch, flavored water, and the like. Thebeverage substance26 may be provided in different form such as powder, liquid, and a mixture of powder and larger ingredients as discussed below. The brewing mechanism may adjust the temperature of the water depending on the type ofbeverage substance26 packed within thepouch152. For instance, for coffee, the water temperature injected by theinlet piercing element100 may be from about 80° C. to about 95° C.; and for brewing tea, the water temperature may be less such as from about 70° C. to about 85° C. In order to brew baby milk formula, thepatch142 may be formed from a filtering material to purify the water injected into thethird chamber136 before passing onto thesecond chamber38 by the one-way valve146. Thepatch142 formed from a water filtering material may remove bacteria and microbial hazards from the water injected by theinlet piercing element100. The one-way valve146 may isolate theinlet piercing element100 from thepouch152 so that thebaby milk formula50 is not contaminated by the inlet piercing element and vice versa. And for brewing baby formula, the water temperature injected by theinlet piercing element100 may be from room temperature to about 60° C., and in particular from about 40° C. to about 50° C.

FIG. 10C illustrates that thepod10 may be packed with thebeverage substance26 within thesecond chamber38 of thecontainer12. In this embodiment, thebeverage substance26 may be a mixture ofpowder156 and largersolid ingredients158. Without the filter incorporated into thepod10, the size of thegap106 between therim22 and thesidewall18 may be larger than thegap106 illustrated inFIG. 10A where thefilter24 is utilized. This may allow the largersolid ingredients158 to pass through thegap106 once thepeelable portion104 has been separated from thesidewall18 in a manner discussed above. For example, thebeverage substance26 may brew a cup of soup with thepowder156 that dissolve with heated water to form the broth, and thesolid ingredients158 forming the vegetables. This allows thepod10 to brew a cup of beverage with a mixture of different size ingredients within thebeverage substance26 utilizing onepod10 rather than needing to utilize two separate packages: one pod to brew the powder base broth, as an example; and a separate pouch to pack the solid ingredients to be mixed into the broth.

FIG. 11A shows a cross-sectional view of an alternative embodiment of asecond portion204A configured to work with thepod10 having anirregular sidewall18A, where thesecond portion204A may be orientated to receive thepod10 such that the angle θ may be between 0° and 90°, and in particular, the angle θ may be greater than about 15°. Theirregular sidewall18A may form alarger pathway40 between thesidewall18A and thesidewall32 of thefilter24. On the outer side of thesidewall18A, a number ofchannels290 may be formed. Thesecond portion204A may include aholder208A having aninner sidewall250 configured to conform to the shape of the outer configuration of thesidewall18A of thepod10 such as thechannels290. In this example, theinner sidewall250 may have a correspondingcorrugated configuration252 sized to receive thepod10. Theholder208A may have afirst slot254 and asecond slot256 adapted to receive afirst bumper258 and asecond bumper260, respectively. In particular, other than the area between the two

slots

254 and256, theinner sidewall250 of theholder208A may have corrugated configuration sized to conform to the outer corrugated configuration of thesidewall18A. Theholder208A may also have amold262 between the two

slots

254 and256 such that when thepod10 is inserted into theholder208A, a space264 may be formed between thesidewall18A and themold262. The space264 may be greater than the rest of thespace266 formed between thesidewall18A and the rest of theinner sidewall250. Themold262 may have acavity268 adapted to reshape thesidewall18A as discussed in more detail below. The first and

second bumpers

258 and260 may have first and second proximal ends270 and272, respectively, adapted to pivot about ahinge274 such that the distal ends276 and278 of the

respective bumpers

258 and260 may move in and out of their

corresponding slots

254 and256 as indicated by their

respective direction arrows

280 and282. Thehinge274 may be spring loaded such that the first and

second bumpers

258 and260 may be biased toward a retracted position as illustrated inFIG. 11A. The brewing mechanism may also include

stoppers

284 and286 positioned to engage with their

respective bumpers

258 and260 as thefirst portion202 fully engages thesecond portion204A as discussed above in reference toFIG. 6C. Note that it is within the scope of the invention to have themold262 be detached from theholder208A and be associated with the

bumpers

258 and260. In this embodiment, the holder may have an elongated slot between the two

slots

254 and256. Moreover, theholder208A may not have themold262 to allow the sidewall108A to expand into the enlarge space264 created by the absence of the mold.

FIG. 11B shows thefirst portion202 fully engaged with thesecond portion204A but prior to the brewing process as illustrated inFIG. 6C. As thesecond portion204A moves from the position shown inFIG. 6A towards6C, the angle0 reduces such that the first and

second bumpers

258 and260 engages with their

respective stoppers

284 and286, which cause the distal ends276 and278 of the

bumpers

258 and260, respectively, to engage with theouter channels290 of thepod10 juxtaposed to the two distal ends. Note that the distal ends276 and278 may engage with theouter channels290 more securely compared to a smooth surface since the channels formed a cavity that conforms to the shape of the distal ends. However, it is within the scope of the invention to have thesecond portion204A work with thepod10 with the smooth exterior sidewall or any other outer configuration of thesidewall18A. The two

distal ends

276 and278 may pivot about thehinge274 such that the two

distal ends

276 and278 may pinch their corresponding outer cavities form by thechannels290 together such that the size of thegap106 formed between the twoouter channels290 being pinched may be enlarged to improve the flow of beverage draining out of thepod10.

FIG. 11C illustrates thesidewall18A of thepod10 being reshaped during the brewing process within thesecond portion204A. As heated water is injected into thepod10 during the brewing process, the temperature and the pressure within thepod10 may increase such that thesidewall18A adjacent to themold262 may be reshaped. Other than the area between the two

slots

254 and256, theinner sidewall250 of theholder208A may have corrugated configuration sized to support and retain the shape of thesidewall18A such that the expansion of thesidewall18A where it is supported by theinner sidewall250 may be minimized. The enlarged space264 (seeFIG. 11A) between themold262 and the juxtaposed portion of thesidewall18A, however, allows theouter channels290 pinched by the two

distal ends

276 and278 to stretch and expand into thecavity268 formed within themold262, thereby further enlarging thegap106 compared to thegap106 shown inFIG. 11B, prior to the brewing process, to reduce the flow rate of the beverage draining from thepod10. The reduced or slower flow rate of the beverage through thegap106 may minimize the turbulence in order to minimize splattering of the beverage as the beverage drains from thegap106.

FIG. 12A shows a cross-sectional view of another embodiment of apod10A incorporating ashield302 between thefilter24 and thecontainer12. Theshield302 may have asidewall304 that extends upwardly from abottom edge306 and then extends outwardly from acorner308 to form afirst extension310A and asecond extension310B. Thefirst extension310A may extend outwardly in a lateral manner and thesecond extension310B may extend in an oblique or slanted manner relative from thefirst extension310A such that thesecond extension310B may face towards thebase16 of thecontainer12. Theshield302 may have a plurality ofribs312 protruding out from thesidewall304 and extending between thebottom edge306 and thecorner308. Theribs312 may maintain apathway314 between the two

sidewalls

18 and304 to allow the beverage within thepod10A to flow along thepathway314. Thesidewall304 may also have a plurality ofholes320 to allow the beverage to pass through thesidewall32 of thefilter24 and pass throughholes320 and flow along thepathway314. Theshield302 may have a line ofweakness316 between the first and

second extensions

310A and310B to allow thesecond extension310B to move upwards to be aligned laterally relative to thefirst extension310A as thecover62 fully closes relative to theholder66 in a manner described above in reference toFIGS. 3A and 3B.

Thepod10A may have thefirst extension310A of theshield302 between therim22 and theledge36 of thefilter24; and theledge36 between thefirst extension310A and thelid14. Thefirst extension310A may be hermetically bonded to therim22 via thefirst bond50; theledge36 may be hermetically bonded to thefirst extension310A via thesecond bond52; and thelid14 may be hermetically bonded to theledge36 via thethird bond354 such that once thepod10A is assembled, thepod10A may be airtight to substantially prevent air, oxygen, gases, and moisture from entering and escaping from the pod during manufacturing, handling, shipping, storing, and normal brewing process. That is, thepod10A may hermitically seal the beverage substance within thecontainer12 to substantially maintain the freshness of the beverage substance therein within an acceptable tolerance level for a desired period of time. In this embodiment, thefirst bond50 may be a peelable bond, and the second and third bonds may be either peelable or more permanent bond. Therim22 may have a line ofweakness42 such that when thepod10A is used in the second orientation in the manner described above in reference toFIGS. 6-11, a portion of therim22 may separate from thesidewall18, along with the adjacent portion of theshield302, as discussed below, to form a gap between thesidewall18 and theshield302.

Alternatively, theshield302 may be formed from a polymer material such as polypropylene and polyethylene such that thefirst extension310A may be ultrasonically welded to therim22 with sufficient bonding, as discussed in more details below, to hermitically seal the beverage substance within thecontainer12 yet allow thefirst extension310A to peel away from therim22 upon an application of sufficient force upon thesecond extension310B. In the event that the weld between the first second310A and therim22 may be stronger than the force applied upon thesecond extension310B such that the first second310A does not peel away from therim22, a portion of therim22 may separate from thesidewall18, along with the adjacent portion of theshield302 to form a gap between thesidewall18 and theshield302, as discussed in more detail below.

FIG. 12B shows a perspective view of theshield302 having thesidewall304 with plurality ofribs312 extending between thecorner308 and thebottom edge306 along alongitudinal axis318. Thesidewall304 may have a plurality ofholes320 between theribs312. Alternatively, thesidewall304 may not have theholes320. Instead, thesidewall304 may be formed from a web ofribs312 with space between theribs312. This may allow thesidewall304 to be more flexible to allow thesidewall304 to conform to thefilter24 during the brewing process when thepod10A is brewed in the second orientation. Thefirst extension310A may extend outwardly from thecorner308 with thesecond extension310B further extending in a downward sloping manner relative to thefirst extension310A. Thesidewall304 of theshield302 may form anopening322 defined by thecorner308. Theopening322 may receive thefilter24, and theledge36 may be bonded to thefirst extension310A.

When thepod10A is used in the second orientation, theshield302 may support and protect thefilter24 from the separatingelement216 utilized to separate therim22 from thesidewall18 as illustrated inFIGS. 6 through 11, for example. That is, theshield302 may support and protect thefilter24 from unintentionally tearing along theledge36 or thecorner34 of the filter by the separatingelement216 as thefirst portion202 moves towards thesecond portion204, or vice versa, and in combination thereof. This may allow flexibility in terms of the type of filter materials that may be utilized to form thefilter24 of thepod10A. For instance, thefilter24 may be formed from commercially available permeable materials such as paper or polymer materials but each material has its own attributes, which may be suitable as a filter depending on the application and the type of beverage being brewed. In general, paper materials are commonly used to form the filter within the single-serve pods, such as in K-Cup pods, for the following attributes: (1) paper filter is generally biodegradable; (2) paper filter generally allows the beverage to pass without altering the taste of the beverage; (3) paper generally bonds well to the interior sealing layer of the container such that the pods can be produced at a high rate; (4) once the paper material has been formed into its intended cup like shape, it generally maintains its desired shape such as when the filter sidewall has been corrugated to increase the surface area of the sidewall to allow the beverage to flow more freely; and (5) paper filters generally cost less than the polymer materials like nylon.

While there are a number of positive attributes to utilizing paper filter for the application of single-serve pods, the paper filter, however, is more prone to tearing and puncturing, especially when it is wet and under increase internal pressure during the brewing process, compared to a nylon filter, for example. Moreover, thefilter24 may be more susceptible to tearing when the pod is brewed in the second orientation versus the first orientation as discussed above. A thicker, denser, and/or stronger paper filter may be utilized to reduce the risk of tearing and puncturing but such thicker paper filter may restrict the flow of beverage therethrough, which can alter the taste of the beverage. With theshield302 protecting thefilter24 from tearing and puncturing, however, a traditional paper filter material may be utilized to form thefilter24 within thepod10A to take advantage of the positive attributes of the paper filter as noted above. It is however, within the scope of the invention to utilize polymer material, thicker paper filter, and paper filter in a single layer or in multiple layers where different materials may be combined to form a unitary layer with the variety of pod embodiments disclosed in this application. Moreover, when thepod10A is brewed in the second orientation, theribs312 extending along thelongitudinal axis318 and protruding outwardly from thesidewall304 may maintain thepathway314 between the two

sidewalls

304 and18 to ensure that the beverage may flow along thepathway314 to drain the beverage near the top side of thepod10A.

FIG. 12C shows yet another embodiment of apod10B incorporating ashield302A where thesidewall304 in this embodiment may be shorter than the sidewall illustrated inFIG. 12A. Moreover, thefilter24A in this embodiment may have itssidewall32 extending upwardly from the bottom30 and terminate at adistal end80. Thesidewall32 of thefilter24A may be bonded to thesidewall304 of theshield302 at afourth bond area324, which may be near thedistal end80. Thefilter24 may be bonded to thesidewall304 in a variety of methods known to one skilled in the art. For instance, thefirst bond area324 between thesidewall304 and theside wall32 may be formed utilizing similar heat sealed or ultrasonic weld method utilize to bond traditional paper filter to the interior sealing layer of thecontainer12 adjacent to thedistal end80. Thefirst extension310A of theshield302A may be sandwiched between therim22 and thelid14. Thefirst extension310A may be bonded to therim22 via thefirst bond50; and thelid14 may be bonded to thefirst extension310A via thesecond bond52. In this embodiment, thefirst bond50 may be a peelable bond, and the second bond may be either peelable or more permanent bond. Thesecond extension310B may extend outwardly in an oblique manner relative to thefirst extension310A. Theshield302 may have a plurality ofribs312 protruding from thesidewall304 to maintain thepathway314 between the two

sidewalls

304 and18 in a manner discussed above. When thepod10B is brewed in the second orientation, the separatingelement216 or the hook288 may abut against underside of thesecond extension310B near theoblique location56 to peel away thefirst extension310A from therim22 to allow the beverage within thepod10B to drain along thepathway314 formed between the two

sidewalls

304 and18. Note that thefirst extension310A and therim22 may have sufficient structural rigidity to peel thefirst extension310A away from therim22 more readily along the peelablefirst bond50 than other areas of thecontainer12. That is, the outer diameter of therim22 may be less than the diameter of theoblique location56 formed on theshield302 to allow theseparating element216 to abut against theoblique location56 such that the force applied by the separatingelement216 near theoblique location56 may transfer to thefirst extension310A and the rigidity of therim22 may aid in thefirst extension310A peeling away along thefirst bond50 in a consistent manner. As such, in this embodiment, theshield302 may be separated or peeled away from therim22 to allow the beverage to drain via a newly formed gap between thefirst extension310A and therim22 without the need for a line of weakness on therim22. Moreover, with thepod10B having thefilter24A bonded to thesidewall304 along thefourth bond area324, the overall thickness of the rim area including thelid14, first extension301A, and therim22 may be less than the thickness of the rim area including the thickness of the filter disclosed inpod10A as disclosed above in reference toFIG. 12A. The reduced thickness of the rim area of thepod10B may be similar to the thickness of the rim area of K-Cup pod such that thepod10B may work readily with the brewers in the market that work with K-Cup pods.

FIG. 12D shows an alternative embodiment of thepod10B illustrated inFIG. 12C. In this embodiment, thecontainer12 may be viewed as divided into at least two parts: afirst part82 and asecond part84. Thefirst part82 may be theshield302A, and thesecond part84 may be a revisedcontainer12A with asidewall18B that terminates at the bend location or itsdistal end20B without extending outwardly to form therim22. Thefirst extension310A of theshield302 may nest over thedistal end20B ofcontainer12, and the exterior side of thesidewall304 may be bonded to the inner side of thesidewall18B via afifth bond326, and thelid14 may be bonded to thefirst extension310A via thesecond bond52. Thefirst part82 andsecond part84 may be bonded together via thefifth bond326 so that both parts may be hermitically bonded together in a manner described above such that air, oxygen, gases, and moisture do not pass through the bonded area during the normal manufacture, shipping, inventory, and use of thepod10B. In particular, thefifth bond326 may be a peelable bond and thesecond bond52 may be either peelable or permanent bond. As such, thefirst extension310A of theshield302 may form therim22 of thecontainer12A. When thepod10B is brewed in the second orientation, the separatingelement216 or the hook288 may abut against underside of thefirst extension310A to peel away theshield302 from thedistal end20B of thecontainer12A along thefifth bond326 to allow the beverage within thepod10B to drain along thepathway314 formed by theribs312 or near the top side of thepod10B.

FIG. 12E shows that thefifth bond326 may cover the area around thesidewall304 and thefirst extension310A near thedistal end20B to provide a larger bonding area between theshield302 and thecontainer12A to improve the integrity of the bond between the two parts. Note that it is within the scope of the invention to have the interior sealing layer of thesidewall18B be a peelable bond layer which is then heat sealed to the exterior layer of theshield302 at thedistal end20B rather than utilizing thefifth bond326. Alternatively, the exterior layer of the shield may be a peelable bond layer that is heat sealed to the interior layer of thesidewall18B rather than utilizing thefifth bond326. In addition, thesecond extension310B may be shorter than the same extension illustrated inFIG. 12D. A shortersecond extension310B may provide a stiffer extension so that a force applied to the shortersecond extension310B by the hook288, for example, may be transferred more efficiently to thefirst extension310A to peel thefirst extension310A away from thesidewall18B.

FIG. 13A shows analternative pod400 in an upright expanded perspective view along alongitudinal axis402 configured to brew beverages such as coffee and espresso;FIG. 13B shows an inverted expanded perspective view of thepod400 along theaxis402 to show the top and bottom views, respectively, of the various components of thepod400; andFIG. 13C shows a plurality of holes formed within the base of the filter for brewing low pressure coffee, as discussed in more detail below. Thepod400 may include acontainer404, afilter406 adapted to receive beverage ingredient (not shown), adistributor412, and alid414. Thecontainer404 may have a base416 that extends upwardly to form asidewall418 and then extends outwardly to form arim420 defining anopening460. Thecontainer404 may be formed from a variety of materials and from single or multilayered sheets sandwiched together to form a hermetically sealed barrier to protect the beverage ingredients contained therein from atmospheric oxygen entering the container. The container may be formed from a variety of materials known to one skilled in the art. In this regard, thecontainer404 may be formed in a manner described in U.S. Pat. No. 10,336,498 issued Jul. 2, 2019, entitled “CONTAINER WITH IMPROVED PUNCTUREABILITY”, by Foster et al., which is hereby incorporated by reference in its entirety. In particular, thecontainer404 may be formed by a variety of molding process such as injection molding and thermoforming process of thermoplastic material, which may be substantially impermeable and imperforate. For example, the thermoplastic materials may include polyolefins such as polypropylene and polyethylene, polystyrene, nylon, and other polymers; and in particular, thermoplastic material may be a bio-based resin, readily recyclable, and/or comprise of at least a portion of recycled material such as a recycled polypropylene base resin.

Thefilter406 may have a base422 that extends upwardly to form asidewall424 and then extends outwardly to form anextension426, which may be defined by one or more extensions including afirst extension428 and asecond extension430. Thefirst extension428 may define anopening454 adapted to receive the beverage ingredient (not shown). The first extension may extend outwardly to a predetermined distance as indicated by areference numeral431, and thesecond extension430 may extend farther therefrom outwardly in a beveled manner or downward sloping manner relative to thefirst extension428 towards thebase422. Thefirst extension428 may extend outwardly at a distance, as indicated by thereference numeral431, such that thefirst extension428 may extend farther out laterally than therim420 to allow thefirst extension428 to lay upon or overlap therim420 when thefilter406 is placed within thecontainer404. Thebase422 of thefilter406 may have a plurality ofholes436 where the size and number of theholes436 may be predetermined to control the flow of the beverage through theholes436 to provide a desired pressure within thefilter406, as discussed in more detail below. The base422 may also have at least oneretainer wall432 with a plurality ofslits434, as discussed in more detail below.

Thecontainer404 may be adapted to receive thefilter406 and thefirst extension428 of theextension426 may be releasably sealed or adhered to therim420 of thecontainer404 where upon a force applied to the underside of thesecond extension430, thefirst extension428 may peel, separate, and/or snap off from therim420. In this regard, the releasable bond(s) may be utilized such as the embodiments disclosed in US Published Application No. 2014/0161936, published Jun. 12, 2014, entitled CONTAINER WITH REMOVALE PORTION by Trombetta et al., which is hereby incorporated by reference in its entirety. Alternatively, thefirst extension428 of thefilter104 may be ultrasonically sealed to therim420 of thecontainer404 such as with the linear or torsional ultrasonic welding as known to one of skilled in the art. For instance, torsional welding method may apply high-frequency vibrational energy tangentially as disclosed in U.S. Pat. Nos.: (1) U.S. Pat. No. 10,554,004 entitled “Sonotrode, device and method for producing a join” issued Feb. 4, 2020; and (2) U.S. Pat. No. 10,532,424 entitled “Device for welding components by means of ultrasound” issued Jan. 14, 2020, both Assigned to Telsonic Holding AG, which are hereby both incorporated by references in their entirety. Alternatively, liner ultrasonic welding method may be utilized to weld thefirst extension428 to therim420.

FIG. 13A shows that therim420 of thecontainer404 may have anenergy director437 protruding upwardly to engage with the underside of thefirst extension428 of thefilter406 to absorb the energy from an ultrasonic welding method or apparatus in a more predetermined manner. A variety of welding methods known to one skilled in the art may be utilized such as a linear ultrasonic and torsional ultrasonic welding methods such that theenergy director437 protruding from therim420 may melt and infuse with thefirst extension428 of the filter. AndFIG. 13B shows that the underside of therim420 may have a line ofweakness442 similar to the line ofweakness42 discussed above in reference toFIG. 12A such that when thepod400 is used in the second orientation in the manner described below, a portion of therim420 may separate from thesidewall424, along with the adjacent portion of thefirst extension428, as discussed below, to form a gap between the attached portion of therim420 and theextension426.

Thefirst extension428 may have astep403 formed in the inner side of thefirst extension428. Thedistributor412 may have aflange413 that extends outwardly to rest within thestep403 of thefilter406. Thedistributor412 may also have askirt446 adapted to engage with theinner side440 of thesidewall424 juxtaposed to thefirst extension428 such that a portion of theflange413 that extends out from theskirt446 may rest within thestep403 and flush with thefirst extension428.FIG. 13C shows a plurality ofholes436 in thebase422 of thefilter406 where the size and number of theholes436 may be predetermined to control the flow of the beverage through theholes436 to provide a desired low-pressure within thefilter406 to brew coffee for example.

Thedistributor412 may have a base442 with anouter skirt446 adapted to engage with theinner side440 of thesidewall424 juxtaposed to thefirst extension428 such that the base442 may be adjacent to thefirst extension428 of theextension426 when assembled together. Theskirt446 may extend upwardly and/or downwardly to engage with theinner side440 of the sidewall. The base442 may have aprotrusion444 extending towards the inner space within thefilter406. Theprotrusion444 may form acavity462 sized to receive an inlet liquid injection member, as discussed in more detail below, such as an inlet needle to inject heated water into thefilter406. The base442 may have a plurality ofholes448 to allow the heated water to pass therethrough to substantially distribute the water over the opening454 of thefilter406. The size of theholes448 may be less than the average size of the beverage ingredient. This may substantially prevent the beverage ingredient from entering theprotrusion area444 thereby substantially preventing the beverage ingredient from clogging the inlet injection member, which can cause the brewing mechanism to malfunction.

Thesidewall424 may have one ormore ribs425 extending outwardly. The extendingribs425 may be formed on theexterior side427 of thesidewall424 adjacent to theextension426. As thefilter406 is inserted into thecontainer404, the extendingribs425 may engage with thesidewall418 of thecontainer404 to center thefilter406 relative to thecontainer404 such that thefilter406 may be substantially aligned with thefilter406 along theaxis402 of thepod400. Thedistributor412 may be placed over the beverage ingredient packed within thefilter406. Theprotrusion444 may have an inverted bell like shape to enlarge the area of thecavity462 adapted to receive the inlet member of the brewing mechanism. Theenlarged cavity462 may also allow the outer area of thedistributor412 to flex and bend more readily.

The manner in which the beverage ingredient is packed within thefilter406 may be predetermined to control the density of thebeverage ingredient410 therein to substantially prevent air pockets, gaps, and channels from forming within theingredient410 during manufacturing, shipping, handling, and during the brewing process. As a general rule,beverage ingredient410 with greater density may require greater pressure to push the heated liquid through thebeverage ingredient410, which can extract more intense flavor from thebeverage ingredient410 in less time. Once thefirst extension428 of thefilter406 is separated from therim420, as discussed in more detail below, thedistributor412 may flex to substantially contain theingredient410 within thefilter406 to avoid forming air pockets therein. Thelid414 may be placed over thefilter406 and theouter edge450 of thelid414 may be sealed and/or bonded to thefirst extension428 of thefilter406 and a portion of thebase442 of thedistributor412. In particular, thelid414 may be formed from a flexible liner with sufficient tensile strength to resist tearing due to the high-pressure during the brewing process.

The pressure developed within thebeverage ingredient410 can determine the type of beverage brewed such as coffee under lower pressure and espresso under higher pressure. A number of other factors can determine the pressure developed within thebeverage ingredient410 such as the pressure and temperature of the heated water injected into the beverage ingredient, the grind size and density of the beverage ingredient, the size and number ofholes436 in thebase422 of thefilter406, the depth of the beverage ingredient, and etc.FIG. 13C shows an enlarge view of the base422 having a predetermined number ofholes436 sized to brew low pressure coffee by allowing the beverage to pass therethrough but substantially prevent the beverage ingredient packed within thefilter406 from passing through the holes due to pressure within the filter during the brewing process. For instance, thesidewall424 may be substantially solid to direct most of the beverage, if not all, to pass through theholes436 on thebase422. Moreover, the extendingribs425 extending from thesidewall424 may substantially maintain its shape under the desired brewing pressure conditions. The number and/or size of theholes436 formed in thebase422 may be predetermined to provide sufficient resistance to flow of beverage to develop the desired brewing pressure within the beverage ingredient to brew a desired beverage. For example, to brew espresso under high-pressure from about 6 to 15 bars, the coffee beans may be finely grounded where the average grind size may be from about 40 to about 450 microns, and to brew coffee under low-pressure from about 1 to 4 bars, the coffee may be grounded more coarsely where the average grind size may be from about 500 to about 1,000 microns; and to substantially prevent the grinds from passing through the holes, the size of theholes436 may be less than the average grind size of the coffee grounds. The holes may have a variety of shapes such as circular, square, rectangular, regular and irregular configuration.

Along with the size of theholes436, the number ofholes436 provided in thebase422 may be predetermined to develop the desired pressure within thefilter406 to brew the intended beverage such as espresso or coffee. That is, the brewing mechanism may inject heated water into thepod400 at a pressure up to about19 bars but some of the pressure may be released through the coffee ground and through thefilter406 such that the espresso flavor beverage may be extracted from the finer coffee ground at about8 bars, for example, with the difference of11 bars of pressure being released, in this example. That is, the pressure within the filter may largely depend upon the size of the beverage ingredient and the size and number ofholes436. For instance, for low-pressure coffee, coarser ground coffee may be packed within thefilter406 and the size and number ofholes436 may be greater than that of theholes436 to brew espresso, and substantial pressure may be released through the coffee ground and through thefilter406 such that coffee may be extracted from the coarser coffee ground at about 3 bars, for example, with the difference of16 bars of pressure being released.

In general, for low-pressure coffee, the size of theholes436 may be less than an average grind size or less than the lower end of the distribution of the grind sizes to brew coffee where the average grind size may be from about 450 to about 1,000 microns; and in particular from 500 to about 700 microns. Note that some soluble may have an average grind size of about 1,000 to 2,500 microns. For instance, coffee ground may have grind size distribution from 500 to 700 microns with an average or mean grind size of about 600 microns. With such grind size distribution and average, the size of theholes436 to brew coffee may be less than about 600 microns or less than 500 microns to substantially prevent coffee ground from passing through the holes and to release the pressure within the coffee grounds to brew coffee. Alternatively, thepod400 may include a paper filter between theholes436 and the coffee ground, although not necessary, to allow the beverage to pass while preventing the smaller coffee sediments from passing therethrough during brewing process. Moreover, it is within the scope of the invention to have the size and number ofholes436 in the base422 to be independent of the grind size of thebeverage ingredient410 where the size of theholes436 may be sized to substantially prevent the ingredient sediment from passing through theholes436.

FIG. 13B shows at least oneretainer wall432 extending from thebase422. In particular, thebase422 may have a plurality ofretainer walls432 extending therefrom with layers ofretainer walls432 forming a pathway between twoadjacent retainer walls432, and with a plurality ofslits434 on each of theretainer wall432. Theretainer walls432 may have distal ends that contour the shape of the inner side of thebase416 of thecontainer404. The width of theslits434 may be sized to serve as a second filtering step such that beverage ingredients that may have pass through theholes436 may be substantially prevented from passing through theslits434 while allowing a predetermine fine beverage ingredients to pass therethrough.

FIG. 14A shows an expanded perspective view of analternative pod400A along its longitudinal axis configured to brew high-pressure beverages such as espresso; andFIG. 14B shows an inverted expanded perspective view of thepod400A to show the top and bottom views, respectively, of the various components of thepod400A. Thepod400A may include thesame container404, thedistributor412, and thelid414 as discussed above in reference toFIG. 13A. Thepod400A includes asecond filter406A adapted to receive beverage ingredient (not shown) to brew high pressure beverages such as espresso. Thefilter406A may haveribs425A formed on theexterior side427A of thesidewall424A, and theribs425A may extend from theextension426A to thebase422A or some portion thereof. Theribs425A may provide structural support to thesidewall424A of thefilter406A to substantially prevent thesidewall424A from expanding, and maintaining a pathway open between the sidewalls424A and418 during a high-pressure brewing process. Thefilter406A may have astep403A in the first extension428A adapted to receive thesame distributor412 in a manner discussed above.FIG. 14C shows a plurality ofholes436A in thebase422A of thefilter406A where the size and number of theholes436A may be predetermined to control the flow of the beverage through theholes436A to provide a desired high-pressure within thefilter406A to brew espresso for example. In this regard, the size of theholes436A for the high-pressure brewing applications may be smaller than theholes436A for the low-pressure brewing applications; and the number ofholes436A provided in thebase422A may be fewer than theholes436 provided in thebase422.

FIG. 15A shows enlarge views of theextension426 of thefilter406 and therim420 of thecontainer404 of thepod400 in reference toFIG. 13A. Thefirst extension428 may have thestep403 formed in the inner side of thefirst extension428. Thedistributor412 may have aflange413 that extends outwardly to rest within thestep403 of thefilter406 such that the top surfaces of theflange413 and thebase442 of thedistributor412 may be substantially flush with the first extension428A. Theenergy director437 may protrude upwards from thetop side421 of therim420, and the line ofweakness442 may be formed on theunderside423 of therim420. In this embodiment, theenergy director437 may be located at about the midpoint between thedistal end429 of the rim and thesidewall418 of thecontainer404. And the line ofweakness442 may be between theenergy director437 and thesidewall418 of thecontainer406 such that the line ofweakness442 divides therim420 into anouter section425 and aninner section427. Theenergy director427 may have a variety of configuration such as a semi-circular, square, rectangular, triangular shape and the like. For instance,FIG. 15B illustrates that the energy director may have a triangular shape with a base width “B” from 0.3 mm to 1.0 mm, a height “H” from 0.3 mm to 1.0 mm, and a tip width “T” form 0.02 mm to 0.2 mm; and in particular, the triangular energy director may a base width from 0.4 mm to 0.6 mm, a height from 0.4 mm to 0.8 mm, and a tip width form 0.05 mm to 0.10 mm. In particular, the energy director may be sized and the ultrasonic energy applied to theenergy director437 may be such that the sealing force around the circumference of therim420 may be within a predetermined sealing force range such as: from 10N to 40N force (Newton Force); and in particular, from 15N to 35N force; and further in the range from 20N to 30N force. These sealing force ranges may allow thepod400 to hermitically seal the ingredients within the pod while substantially preventing therim420 of the container from unintentionally separating from thefirst extension428 of the filter prior to brewing the pod such as during handling and shipping. Thecontainer404 and thefilter406 may be made of similar material such as polypropylene or polyethylene where ultrasonically welding two similar materials together may result in more consistent seal between theenergy director437 and thefirst extension428 around therim420 of the container; and both parts may be made through an injection molding process to form theenergy director437 and the line ofweakness442 in thecontainer404 in a more consistent manner. Note that it is within the scope of the invention to form the container through blow molding and thermoforming methods. In addition, providing theenergy director437 on therim420 of thecontainer404 may provide a more consistent sealing force between thelow pressure filter406 and thehigh pressure filter406A since thesame container404 with thesame energy director437 is utilized for both

filters

406 and406A such that the variances in the dimensions of theenergy director437 may be minimized.

In general, the line ofweakness442 may be formed such that the force required to separate theouter section425 from theinner section427 of therim420 may be in the upper range of the force required to separate theenergy director437. For example, if theenergy director427 is designed to separate between 20N to 30N based on predetermined ultrasonic energy delivered by the welding machine, then the line ofweakness442 may be designed to separate at about 30N. This way, ifenergy director437 does not separate upon an application of about 30N due to variances in the size of theenergy director437 and/or the amount of energy applied to theenergy director437, then the line ofweakness442 may separate such that theouter section425 of therim420 may peel away withfirst extension428, as discussed in more detail below, thereby forming a gap between theinner section427 and thefirst extension428 to allow the beverage to drain via the gap. That is, theenergy director437 and the line ofweakness442 may provide two independent means of separating thefirst extension428 from therim420 where the line ofweakness442 may serve as an alternative separation area in the event theenergy director437 does not separate as intended, or vice versa.

FIG. 15C shows an alternative embodiment of thecontainer404 where theenergy director437 and the line ofweakness442 may be located closer to thedistal end429 of therim420 relative to the locations of the two respective elements illustrated inFIG. 15A. This may allow the force applied to theunderside430A of thesecond extension430 to be in closer proximity to theenergy director437 such that the applied force may be more directly applied to theenergy director437 for more consistent separation of theenergy director437. Moreover, the width of theinner section427 may be wider relative to the embodiment illustrated inFIG. 15A such that in the event that the line ofweakness442 separates rather than theenergy director437, theinner section427 may serve as a funnel to drain the beverage more smoothly.

FIG. 15D illustrates another alternative embodiment where theenergy director437 may protrude downwards from the underside428A of thefirst extension428, and the line ofweakness442 formed on theunderside420A of therim420. Note that it is within the scope of the invention to have the line ofweakness442 on thetop side420B of therim420.

FIG. 16A shows thepod400 ofFIG. 13A assembled such that theretainer walls432 extending from thebase422 of thefilter406 may be adjacent to thebase416 of thecontainer404. Note that apathway455 may be formed between the two

sidewalls

418 and424. During the assembly process, thecontainer404 may be placed inside an opening formed within a platform and thefilter406 may be placed inside such that thefirst extension428 may rest upon theenergy director437 protruding from therim420, in a manner discussed above. Ultrasonic welding may apply energy over thefirst extension428 or on theunderside423 of therim420 to infuse theenergy director437 to thefirst extension428. Note that with thebase422 of thefilter406 being adjacent to thebase416 of thecontainer404, thepod400 may be utilized in the second orientation but may not be utilized in the first orientation since there is no room for the outlet piercing element to pierce through thebase416 of the container and enter thecontainer404 due to thebase422 of the filter.

FIG. 16B shows an alternative embodiment of the pod400B where thebase422 of thefilter406 may be apart from thebase416 of thecontainer404 such that achamber470 may be formed between the two

bases

416 and422 to allow the tip of the outlet piercing element to pierce through thebase416 and enter thechamber470. This may allow the pod400B to brew in the first and second orientations.

FIGS. 17A through 17D show cross-sectional views of thepod400 in different stages to illustrate a manner and method of brewing a beverage with thepod400. In this example,FIG. 17A shows thepod400 in a substantially horizontal position or second orientation as discussed above, packed withbeverage ingredient410 within thefilter406. In the second orientation, thepod400 may be juxtaposed to aninlet member500 having aninlet end502 and atip504 with agasket506 therebetween. Themember500 may be adapted to slide relative to thepod400 as indicated by the double endeddirection arrow508, or the pod may be adapted to slide relative to themember500, or both

elements

500 and400 may be adapted to slide or move relative to each other simultaneously or sequentially. Themember500 may be positioned relative to thepod400 such that thetip504 may be juxtaposed to thelid414 in order to penetrate thecavity462 of thedistributor412. Thepod400 may also be juxtaposed to a detachingmember510 position behind thesecond extension430 at about the six O'clock position. The detachingmember510 and thepod400 may be adapted to slide relative to each other as indicated by the double endeddirection arrow512 where one or both

elements

400 and510 may move relative to each other simultaneously or sequentially.

FIG. 17B shows that to begin the brewing process, theinlet member500 may pierce, puncture, or cut through thelid414, or use any other apparatus or method known to one skilled in the art, and thetip504 may rest within thecavity462, and thegasket506 may engage with thelid414 surrounding themember500 to substantially prevent the water from leaking out of the opening between themember500 thelid414 formed by the punctured hole within the lid. Thedetaching mechanism510 may move towards an extended position as indicated by thedirection arrow512 to engage with thesecond extension430 to separate thefirst extension428 from therim420 sealed by theenergy director437 near the six O'clock position thereby forming agap484 between theextension426 and therim420 that may extend from about four O'clock to about eight O'clock positions; and in particular from about five O'clock to about seven O'clock positions. Note that in this example, the force applied by thedetaching mechanism510 may be greater than the sealed force provided by theenergy director437 such that thefirst extension428 may separate from therim420.

Thesecond section430 may taper towards thebase416 of thecontainer404 such that the underside of thesecond section430 may form a concave shape or hook to allow the detachingmember510 to engage with the underside of thesecond section430 to separate thefirst extension428 from therim420 more consistently. The newly formedgap484 may form a part of thesecond pathway455 between the two

sidewalls

418 and424 and also between the adjacent extendingribs425 to allow the beverage formed within thepod400 to flow along thesecond pathway455 and drain through thegap484, as discussed in more detail below.

FIG. 17C illustrates that as the detachingmember510 moves further towards theinlet member500 as indicated by thedirection arrow512, thesecond extension430 may flex to allow the detachingmember510 to pass and rest on the opposite side of the extension such that the detachingmember510 may not interfere with the beverage draining out of thegap484. Once thegap484 is formed, a combination of therim420 and the concave shape ofsecond extension430 that extends downwardly may act as a spout to allow the beverage to pour from thegap484 in a smooth manner to minimize spattering of the beverage. This may provide a clear path for the beverage to drain from thepod400 without coming to contact with the brewing mechanism to avoid contaminating the beverage, as discussed in more detail below.

FIG. 17D shows theinlet member500 injectingheated water514 into thecavity462, and theheated water514 may flow along the path as indicated by the

direction arrows

572 and574, and thebeverage596 extracted from thebeverage ingredient410 may flow along the path as indicated by the

direction arrows

576,578, and580, and drain out of thegap484 as indicted by thedirection arrow590 and pour thebeverage596 into amug594. Accordingly, once thebeverage596 passes through theholes436, thebeverage596 may flow along thepathway455 and drain out of thegap484, and pour into themug594 unobstructed by the brewing mechanism to substantially avoid contaminating the beverage and the brewing mechanism.

FIGS. 18A and 18B illustrates the application of the line ofweakness442 where the force applied by thedetaching mechanism510 may be less than the sealing force of theenergy director437 such that thefirst extension428 may not separate from therim420 along theenergy director437 but the force applied by thedetaching mechanism510 may be greater than the strength of the line ofweakness442. Under such circumstances, as illustrated inFIG. 18B, force applied by thedetaching mechanism510 may separate theouter section423 from therim420 along the line ofweakness442 such that theouter section423 may remain attached to thefirst extension428 and forming thegap484 between theinner section427 of therim420 and thefirst extension428 to allow thebeverage596 to drain therethrough. As such, theenergy director437 and the line ofweakness442 may provide two independent means of separating thefirst extension428 from therim420 where the line ofweakness442 may serve as an alternative separation area in the event theenergy director437 does not separate as intended, or vice versa.

While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of this invention. Moreover, various features and functionalities described in this application and Figures may be combined individually and/or plurality of features and functionalities with others. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

Claims

What is claimed is:

1. A beverage pod comprising:

a container having a base that extends upwardly to form a sidewall and extends outwardly to form a rim to define an opening, the rim having a line of weakness defining an outer section and an inner section of the rim where the inner section is juxtaposed to the sidewall;

a filter having a filter base that extends upwardly to form a filter sidewall and extends outwardly to form an extension to define an opening adapted to receive beverage ingredient, where the opening of the container is adapted to receive the filter such that the extension is juxtaposed to the rim of the container; and

an energy director between the rim of the container and the extension of the filter.

2. The beverage pod according toclaim 1, where the energy director protrudes from the rim of the container.

3. The beverage pod according toclaim 1, where the energy director protrudes from adjacent to a distal end of the rim of the container.

4. The beverage pod according toclaim 1, where the energy director protrudes from the extension of the filter.

5. The beverage pod according toclaim 1, where the energy director has a triangular configuration with a base width from 0.40 mm to 0.10 mm, a height from 0.40 mm to 1.00 mm, and a tip width from 0.02 mm to 2.00 mm.

6. The beverage pod according toclaim 1, where the energy director seals the extension to the rim around the circumference of the rim at a predetermined sealing force range from 15N to 40N.

7. The beverage pod according toclaim 1, where the strength of the line of weakness is predetermined to be near the upper range of the predetermined sealing force of the energy director.

8. The beverage pod according toclaim 1, where the line of weakness is between the energy director and the sidewall of the container.

9. The beverage pod according toclaim 1, where the container and filter are made of substantially similar material.

10. The beverage pod according toclaim 1, where the container and filter are made of polypropylene material.

11. The beverage pod according toclaim 1, where the container and filter are formed from an injection molding process.

12. The beverage pod according toclaim 1, where the base filter has holes to allow beverage to pass through the holes.

13. A beverage pod, comprising:

a container having a first part peelably bonded to a second part along a bond area, the first part having a first sidewall that bends at a corner to form a first section and defining an opening around the first section, the second part having a base and a second sidewall that is outside and juxtaposed to the first sidewall to form a pathway between the first and second sidewalls and to have the first section extends outwardly from the second sidewall where the opening defines a top side of the container and the base defines a bottom side of the container, and the bond area is located near the top side of the container;

a filter coupled to the first part such that the filter forms a pocket within the opening to receive a beverage substance within the pocket; and

a lid coupled to the first section of the first part to enclose the opening and to hermetically seal the beverage substance within the container such when the beverage pod is brewed in a first orientation the base is pierced by an outlet piercing element to drain the beverage via the outlet piercing element, and when the beverage pod is brewed in a second orientation at least a portion of the bond area is separated to form a gap between the first and second parts by a separating element to allow beverage to flow along the pathway and drain via the gap.

14. The beverage pod according toclaim 1, where the first sidewall is within the second sidewall and the first sidewall has a plurality of ribs protruding outwardly therefrom to provide the pathway between the first and second sidewalls.

15. The beverage pod according toclaim 1, where the first sidewall has a plurality of holes to allow beverage to pass therethrough.

16. The beverage pod according toclaim 1, where the first section of the first part extends in a lateral manner when the container is in the first orientation.

17. The beverage pod according toclaim 16, where the first part further includes a second section that extends from the first section in a slanted downward manner relative to the first section.

18. The beverage pod according toclaim 17, where the second sidewall extends outwardly to form a rim.

19. The beverage pod according toclaim 18, where the first section of the first part is peelably bonded to the rim of the second part.

20. The beverage pod according toclaim 19, where the rim of the second part has a line of weakness around the second sidewall.

21. The beverage pod according toclaim 1, where the filter has a ledge that is bonded to the first section and the lid is bonded to the ledge of the filter to enclose the opening and to hermetically seal the beverage substance within the container.

22. The beverage pod according toclaim 1, where the filter has a sidewall that extends upwardly from its bottom and terminates at a distal end that is bonded to the first sidewall adjacent to the corner of the first part.

23. The beverage pod according toclaim 1, where the first sidewall has an inner side and an outer side terminating at a distal end, and the first part has an inner side and an outer side

24. The beverage pod according toclaim 1, where the filter has a bottom and the first part has a shield base to support the bottom of the filter such that the first sidewall is between the first section and the shield base.