Recyclable beverage pod with a specialized filter mechanism

Abstract

A recyclable beverage pod with a specialized filter mechanism is enclosed. The beverage pod includes a cavity including a shell, a filter mechanism, a beverage material placed within the filter mechanism, and an airtight lid sealing the filter mechanism and the beverage material within the cavity. Further, the filter mechanism may further include a formed filter material having a tab, wherein the formed filter material is adhered to an interior surface of the shell.

Description

FIELD OF THE INVENTION

[0001] The present invention generally relates to the field of beverage pods. In particular, the present invention is directed to a recyclable beverage pod with a specialized filter mechanism.BACKGROUND

[0002] Since the introduction of single-use containers, such as coffee pods, challenges have arisen in the inability to effectively recycle these small containers. Often, smaller single-use containers are harder to recycle due to their size or due to the contents that are contained within them, such as coffee grounds. Smaller sized single-use containers may slip through the recycling machine, causing jams and difficulties at the recycling plant. Additionally, these single-use containers may be made of plastic which creates environmental concerns due to the challenges of recycling multi-material packaging.SUMMARY OF THE DISCLOSURE

[0003] In an aspect, disclosed is a recyclable beverage pod with a specialized filter mechanism, wherein the beverage pod includes a cavity including a shell; a filter mechanism, wherein the filter mechanism includes a formed filter material having a tab and / or a multiple of tabs; a beverage material placed within the filter mechanism; and an airtight lid sealing the filter mechanism, and the beverage material within the cavity.

[0004] In another aspect, an exemplary method of manufacture of a beverage pod with a specialized filter mechanism may include providing a beverage pod having a cavity including a shell, placing a filter disc into the cavity of the beverage pod, adhering a formed filter material within the cavity of the beverage pod, filling the formed filter material adhered to the interior of the cavity with beverage material, modifying the headspace atmosphere within the cavity, sealing the cavity with an airtight lid, and discharging the beverage pod into a secondary package operation.

[0005] These and other aspects and features of non-limiting embodiments of the present invention will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the invention in conjunction with the accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] For the purpose of illustrating the invention, the drawings show aspects of one or more embodiments of the invention. However, it should be understood that the present invention is not limited to the precise arrangements and instrumentalities shown in the drawings, wherein:

[0007] FIG. 1 is an exemplary illustration of a beverage pod having a specialized filter mechanism, wherein two side views are shown, one wherein an airtight lid and transparent side walls is illustrated, and the other wherein the illustration is without the airtight lid and non-transparent;

[0008] FIG. 2A is an exemplary illustration of a filter mechanism configured with a single tab;

[0009] FIG. 2B is an exemplary illustration of a filter mechanism configured with an additional tab;

[0010] FIG. 2C is an exemplary illustration of a filter mechanism configured with three additional tabs;

[0011] FIG. 2D is an exemplary illustration of a filter mechanism with a tab in a ring configuration;

[0012] FIG. 3A is an exemplary side-view illustration of a filter mechanism including a tab in a handle configuration;

[0013] FIG. 3B is a birds-eye view of an embodiment of the filter mechanism of FIG. 3A illustrating a configuration with one additional tab;

[0014] FIG. 3C is a birds-eye view of an embodiment of the filter mechanism of FIG. 3A, illustrating a configuration with one tab centered across the cavity of the beverage pod:

[0015] FIG. 4 is an exemplary transparent side-view of a filter mechanism including a pull cord;

[0016] FIG. 5 is an exemplary illustration of a filter mechanism including a cinching mechanism;

[0017] FIG. 6 is a flow diagram illustrating an exemplary method of manufacture of a recyclable beverage pod having a specialized filter mechanism.

[0018] The drawings are not necessarily to scale and may be illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to perceive may have been omitted.DETAILED DESCRIPTION

[0019] Beverages, such as coffee and tea, are increasingly prepared using single serve brewing capsules. Note that such “capsules” may also be referred to as “cups” and / or “pods” and those terms may be used interchangeably within this disclosure. Many product benefits are realized when using single serve brewing capsules versus multi-serve bulk packaged roast and ground coffee, bulk packaged tea leaves, and / or bulk packaged drink powders. Capsules offer individual choice, wide availability of variety, fresh flavor and preparation convenience. Additionally, ecological benefits are realized when using single serve brewing capsules versus bulk-packaged drink alternatives, such as, without limitation, roast and ground coffee; most importantly, less waste of the coffee itself. First, unlike a pot of coffee which often is not fully consumed, it is reasonable to expect that beverages prepared using single serve capsules are more likely to be fully consumed. Likewise, unlike a bulk multi-serve container of coffee, which may go stale after opening and before being fully consumed, single serve brewing capsules are protected from oxygen degradation by barrier packaging. Therefore, each individual capsule may remain fresh until brewed, thus avoiding discarding old off-flavor roast and ground coffee. These benefits are advantageous to the ecosystem by aiding in avoiding waste of the valuable coffee crop itself which lends itself to reducing wasted agricultural activity. However, despite their popularity, single serve brewing capsules made from plastic, have been widely criticized for several specific non-ecofriendly features. Namely, the individual packaging of each capsule leads to an increased use of packaging materials per unit, reduced space efficiency, and increased difficulty or the inability altogether to recycle the capsules due to their mixed material components and / or their size.

[0020] The present invention introduces the use of beverage capsules with a specialized filter mechanism for beverage-making appliances. Exemplary embodiments illustrating aspects of the present disclosure are described below in the context of several specific examples.

[0021] Referring now to FIG. 1, an exemplary embodiment of a beverage pod 100 having a specialized filter mechanism is shown. Beverage pod 100 may include a cavity 104 including a shell 108, a filter mechanism 124, wherein filter mechanism 124 includes a formed filter material 128 having a tab 132, a beverage material placed within filter mechanism 124, and an airtight lid 140 sealing filter mechanism 124 and the beverage material within cavity 104.

[0022] With continued reference to FIG. 1, beverage pod 100 may include cavity 104 including a shell 108. Shell 108 of beverage pod 100 may further include one or more surfaces, which may include an interior surface and an exterior surface. As used throughout this disclosure, “cavity” refers to a hole or a hollow space within a solid object. Cavity 104 may be configured in a circular shape, a cylindrical shape, a prism shape, and / or any cup-like shape. In some cases, cavity 104 may include a singular opening. “Shell,” as used throughout this disclosure, refers to the outer structure that defines and encloses a beverage pod's volume. In an embodiment, shell 108 may include a metal material and / or an alloy of metal. For example, and without limitation, shell 108 may include aluminum and / or an aluminum alloy. Other metals may include magnesium, titanium, zinc, and / or copper. Although not commonly used alone in such applications, they may be utilized in combination with aluminum and / or in other aspects of beverage pod 100. In one or more embodiments, shell 108 of beverage pod 100 may include a lip 112, wherein lip 112 provides a surface on which lid 140 may sit and / or be sealed. Additionally, shell 108 of beverage pod 100 may further include a shoulder 116, which may be displaced within cavity 104 below lip 112 of shell 108. Shoulder 116 may provide a surface for which a portion of filter mechanism 124 to sit and / or be sealed. Shoulder 116 may be located near the top of beverage pod 100. “Near,” as used in this context, may be relative to the thickness of filter mechanism 124. In an embodiment, shoulder 116 may be located at least within 0.2 mm to 0.6 mm of lip 112 of beverage pod and at most 12 mm to 19 mm. In most embodiments, shoulder 116 may be located in the upper half or one-third portion of shell 108 height. For example, in some embodiments, shoulder 116 may be located at a height within 90%-99% of the height of beverage pod 100. This may enable lid 124 to seal properly without any interference from filter mechanism 124, while still enabling cavity 104 to hold any necessary components. Embodiments may vary in placement due to certain embodiments containing additional features besides filter mechanism 124 and the beverage material. For example, and without limitation, shoulder 116 may need to be located in closer proximity to the top of shell 108 in an embodiment that includes filter disc 136 and / or a specified headspace. For example, and without limitation, an embodiment which includes filter disc 136 and a specified headspace shoulder 116 may be located at a height within 95%-99% of the height of beverage pod 100. Whereas, in an embodiment not incorporating filter disc 136 and / or a specified headspace, shoulder 116 may be located within 50%-99% of the height of beverage pod 100.

[0023] Continuing to reference FIG. 1, in some embodiments beverage pod 100 may include one or more detents 120 configured to interlock one or more beverage pods 100 together. As used throughout this disclosure, “detent” is a catch in a configuration, which prevents motion until released. In some embodiments, one or more surfaces of shell 108 may include grooves, such as twist grooves, that may be used to stack one or more empty beverage pods 100 on top of, and / or within one another. These twist grooves may be raised on the exterior surface of shell 108 and / or indented into the exterior surface of shell 108. Alternatively, the groove may be on the interior surface of the pod in either a raised or indented formation. The twist grooves may be further described as a lip that protrudes from a surface in a helical groove and / or sets of grooves that configure a helix on one or more surfaces of the pod. This protrusion may be accomplished through the use of additional material being added to one or more surfaces. Alternatively, the protrusion may be accomplished through the stamping of a surface, creating an indentation on a surface and a protrusion on the alternate surface. For example, and without limitation, a twist groove may be stamped onto the exterior surface of a pod, and therefore the protrusion would be on the interior surface, while the indentation would exist on the exterior surface. In an additional nonlimiting example, this would be the opposite should the pod be stamped on the interior surface. As used in this disclosure, “twist grooves” refer to grooves in a helical structure, used to convert between rotational and linear movement or force. Alternatively, in an embodiment, the exterior and / or interior surface of shell 108 may include round, square, and / or oval recesses or detents along the sidewall of the shell 108. As used throughout this disclosure, “recess” is a small space created by building part of the sidewall further back from the rest of the sidewall. In this embodiment when beverage pods 100 are stacked within one another the recesses or detents may interconnect and lock one another together. The alignment of the recesses or detents may be straight, staggered, and / or contain a threaded channel guiding the interlocking feature. In an embodiment, beverage pod 100 may include circumferential beads along the surface of shell 108. In this embodiment, when the pods 100 are stacked and pressed together, they may interconnect and / or lock together. The orientation of the circumferential beads may include a straight and / or aligned pattern of beads. Alternatively, the orientation of the circumferential beads may be staggered and / or in a diagonal pattern in relation to lip 112 of pod 100. The locking mechanism may additionally have a noise confirmation aspect. For example, when one beverage pod 100 is locked into another beverage pod 100 there may be an audible click, indicating that the two beverage pods 100 have been locked together. One or more of these embodiments may align with shell configurations, without limitation, as disclosed in U.S. application Ser. No. 18 / 599,862, filed Mar. 8, 2024 and entitled “HIGHLY RECYCLABLE BEVERAGE PODS AND METHOD OF MANUFACTURE” the entirety of which is incorporated herein by reference. Additionally, the one or more detents 120 may allow for easier storage of beverage pod 100. For example, one beverage pod 100 may be locked into another beverage pod 100 using one of the configurations as discussed above. When one beverage pod 100 is being interlocked with another beverage pod 100, the one or more detents 120 may be complimentary between the interior and exterior wall of each corresponding beverage pod 100. For example, a first beverage pod may have one or more detents 120 that correspond to a second beverage pod 100 having one or more recesses located on the exterior of shell 108. In such an embodiment the second beverage pod 100 would be inserted into the first beverage pod 100 and then locked in by either applying pressure and / or twisting and locking the two pods 100 together.

[0024] In further reference to FIG. 1, In some cases, shell 108 may contain a polymeric coating on an interior surface. The polymeric coating may have a specified weight and thickness. Nonlimiting exemplary embodiments of polymeric coating may include pullulan, hydroxypropyl methylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, polyvinyl pyrrolidone, carboxymethyl cellulose, polyvinyl alcohol, sodium alginate, polyethylene glycol, xanthan gum, tragacanth gum, guar gum, acacia gum, gum arabic, polyacrylic acid, methyl methacrylate copolymer, amylose, high amylose starch, hydroxypropylated high amylose starch, dextrin, pectin, chitin, chitosan, levan, elsinan, collagen, gelatin, zein, gluten, soy protein isolate, whey protein isolate, casein, polysaccharides, natural gums, polypeptides, polyacrylates, starch, gum karaya, and / or mixtures thereof. In an exemplary nonlimiting embodiment, shell 108 may contain a polymeric coating of a specified composition, such as co-extruded polypropylene with a weight of ˜30 g / m2 and a thickness of ˜27 microns. As used in this disclosure, “co-extrusion” is the process of pressing two or more materials through the same mold to produce a single piece. In this process, two or more orifices are arranged in such a way that the fusion and interlocking of the extrusions takes place and a laminar structure is formed before cooling. “Co-extruded polypropylene,”refers to a bi-orientated polymer film obtained from an extrusion process. Qualities the co-extruded polypropylene may possess are good optical qualities, a good barrier towards humidity, and a low barrier towards oxygen. This component may be accomplished in the manufacture of the preliminary shell 108 of beverage pod 100 and / or through a secondary process of dipping, brushing, and / or spraying of the polymeric coating on to the interior surface of shell 108. Furthermore, this process may occur prior to a manufacturing process configured to shape shell 108 and / or after the shaping process has occurred. For example, and without limitation, in an embodiment where stamping is utilized, brushing of the polymeric coat may be applied prior to the shaping of shell 108. The polymeric coating may cover an entire surface and / or be applied to specific areas of an interior surface.

[0025] Continuing to reference FIG. 1, beverage pod 100 may include a filter mechanism 124, wherein filter mechanism 124 may include a formed filter material 128 having a tab 132. “Filter material,” for the purposes of this disclosure, is any material configured to remove impurities or particle from fluid. For example, and without limitation, filter material 128 may be configured to separate coffee and coffee grounds. Likewise, “formed filter material” refers to the filter material being shaped, constructed, or created in a specific way, which may occur during manufacturing and / or some pre-step of manufacturing. In one or more embodiments, this may be accomplished without limitation, as disclosed in U.S. application Ser. No. 18 / 599,862, filed Mar. 8, 2024 and entitled “HIGHLY RECYCLABLE BEVERAGE PODS AND METHOD OF MANUFACTURE” the entirety of which is incorporated herein by reference. Formed filter material 128 may include non-woven plant material, polymeric fibers, and / or a combination there of. As used throughout this disclosure, “non-woven plant material” refers to fabric-like structures made from fibers that are bonded together through various methods, such as heat, chemicals, and / or mechanical processes, rather than being woven or knitted. For example, without limitation non-woven plant material may be manufactured through thermal bonding, wherein heat is applied to melt synthetic fibers, fusing them together. Further, chemical bonding may be used, wherein adhesives are used to bond the fibers. Alternatively, mechanical bonding may be utilized, wherein needle punching or other methods are used to entangle fibers. Non-woven plant material may include cellulose fibers such as, but without limitation, fibers derived from wood pulp, bamboo, rose, Tencel, hemp, and / or the like. For example, and without limitation, this may include materials such as bamboo fabric, hemp fabric, jute, cotton non-wovens, flax (linen), sisal, coir, and / or reed and grass fabrics. Filter material 128 may include a blend of one or more materials to accomplish a specific end goal, such as filtering coffee from coffee grounds. For example, and without limitation, formed filter material 128 may include filter material made of 80 p cellulose fibers, wherein filter material 128 is 80 percent cellulose and 20 percent non-cellulose, which may include polymeric fibers. An exemplary embodiment of filter material 128 may include non-woven polyethylene fabric, such as TYVEK, which is a flashspun high-density polyethylene (HDPE) material known for its unique properties. “Flashspun,” as used in this disclosure refers to a specific manufacturing process used to create non-woven materials, particularly those made from HDPE fibers. For example, in a manufacturing process utilizing flashspinning a polymer may be dissolved in a solvent and then rapidly extruded through a nozzle into a low-pressure environment. The solvent evaporates almost instantly, which may cause the fibers to form and become entangled, resulting in a fabric-like structure. Using such an embodiment of filter material 128 may provide durable, lightweight, water-resistant fiber with the ability to efficiently filter materials 128 and keep costs low. In other embodiments, formed filter material 128 may include any embodiment of filter paper such as coffee filters, other fibrous materials, mesh filters in varying material types, such as nylon and / or stainless steel, and / or ceramic filters. Embodiments of filter material 128 may be used in conjunction with one or more other embodiments of filter material 128 as discussed above.

[0026] Continuing to reference FIG. 1, in an embodiment, filter mechanism 124 may include a pouch configuration, wherein the pouch configuration is sealed with beverage material within. The pouch configuration may be accomplished in one or more manufacturing steps, wherein the beverage material is placed within filter mechanism 124 and then sealed, creating a pouch containing beverage material. Sealing of such an embodiment may be accomplished through heat sealing, adhesive sealing, and / or pressure sealing. In another embodiment, filter mechanism 124 may include an opening. In such an embodiment, filter mechanism 124 may further include a cinching mechanism. As used throughout this disclosure, “cinching mechanism” refers to a device or system designed to tighten or secure an item by providing adjustable tension. For example, tab 132 of filter mechanism 124 may emulate a drawstring and / or tying function. This would allow a user to pull the tab 132 to close off the opening of filter mechanism 124 and pull entire filter mechanism 124 and its contents out of shell 108 of beverage pod 100. This may be accomplished by an embodiment wherein there is a single tab 132 and / or one or more additional tabs 132 as discussed further below. Filter mechanism 124 may be configured in a way that allows tab 132 to fold flat once airtight lid 140 has been placed to seal beverage pod 100. For example, this may be accomplished by sealing filter mechanism 124 to shoulder 116 using a frangible seal. A “frangible seal” refers to a type of seal designed to break or rupture when a certain level of force or pressure is applied. The frangible seal may be accomplished through various manufacturing processes, such as heat sealing, adhesive bonding, and / or ultrasonic sealing. Heat sealing may involve applying heat to bond filter mechanism 124 and shoulder 116. A specific temperature may be chosen so that the seal is strong but will break with minimal force. Adhesive bonding may utilize weak adhesives that provide initial bonding while allowing for easy separation. Whereas, ultrasonic sealing uses high-frequency sound waves to generate heat and create a bond between filter mechanism 124 and shoulder 116. Filter mechanism 124 may include an embodiment in which the tab 132 extends past shoulder 116, wherein shoulder 116 acts as a pivot point from which the tab 132 is folded along. In one or more embodiments, filter mechanism 124 may further include a filter disc 136, wherein filter disc 136 is situated within cavity 104 resting on shoulder 116 of beverage pod 100. In such an embodiment, tab 132 may be frangibly sealed to filter disc 136, enabling the tab 132 to lie flat within beverage pod 100. As used throughout this disclosure, “frangibly” describes something that can be easily broken.

[0027] In further reference to FIG. 1, as used throughout this disclosure, “tab” is a projection or flap connected to an object, used for gripping or holding. In one or more embodiments, formed filter material 128 may include one or more additional tabs 132. For example, and without limitation formed filter material 128 may include two tabs 132 which are situated about the perimeter of formed filter material 128. For example, and without limitation, tab 132 may include two ends, wherein the first end is attached to filter mechanism 124 at one point and the second end is attached diametrically opposite of the location of the attached first end. Alternatively, in one or more embodiments, a first end may be attached to filter mechanism 124 at one point and a second end may be attached to filter mechanism 124 at a point on the same side, but perpendicular to the first end attachment. In such an embodiment there may be one or more of these tabs 132 that may be configured in a handle configuration. In some embodiments, wherein there are one or more tabs 132, they may overlap one another. In an embodiment, there may be a varying number of tabs 132, including one tab 132, two tabs 132, three tabs 132, four tabs 132, six tabs 132, ten tabs 132, and / or as many tabs 132 it might take to cover the surface of shoulder 116. Alternatively, one or more tabs 132 may be centrally located on the formed filter material 128. Tab 132 may embody the configuration of a ring, wherein the tab 132 has a cutout in the center of the body. In such an embodiment, the ring may sit atop shoulder 116 of beverage pod 100, enabling filter mechanism 124 to lay flat and out of the way of the seal of airtight lid 140. In another configuration, tab 132 may include a loop configuration. For example, and without limitation, there may be two tabs 132 on either side of filter mechanism 124 wherein they embody loops, which may be used similarly as one may use handles on a bag. In one or more embodiments, tab 132 may include an undulating border, enabling a user to easily identify the location of the tab 132. As used throughout this disclosure, “undulating” refers to structures or patterns that have a flowing, curvy appearance. This may also be described as having a wavy peripheral of the seal, so that a user may find a tab 132 no matter how they may be holding beverage pod 100. Further, a tab 132 may appear as labeled and / or colored in some way in order to differentiate itself from the background of the rest of filter mechanism 124. In some embodiments, filter mechanism 124 may additionally include a pull cord that may be situated between shoulder 116 and filter mechanism 124. This may be of different material so that a user can easily identify its location. For example, and without limitation this pull cord may include a shiny or metallic appearance and when pulled breaks the frangible seal of filter mechanism 124 and shoulder 116 of shell 108. This may release the tab 132, allowing a user to pull entire filter mechanism 124 from shell 108.

[0028] In further reference to FIG. 1, in an embodiment, tab 132 may be folded inward using various manufacturing processes. For example, folding tabs 132 may occur manually and / or using an automated folding machine. In higher volume production, automated folding machines may be used and may incorporate robotics and / or mechanical arms to handle the pieces. Further, automated systems may undergo precision control, wherein the automated systems are programmed to apply the right amount of pressure and speed to achieve a consistent fold. In some embodiments, automated systems may include machines equipped with sensors that may detect alignment and adjust the folding process in real-time for accuracy. In an embodiment, wherein adhesives are used to secure tabs 132, tabs 132 may be pressed into place to ensure a strong bond.

[0029] With continued reference to FIG. 1, in an embodiment of beverage pod 100 that utilizes filter disc 136, filter disc 136 may be used as previously described and / or to prevent damage to a filter when beverage pod 100 is filled with heavier gram weight beverage materials. Heavier gram weight materials may require a larger and / or deeper filter inside beverage pod 100. The larger and / or deeper filter might obtain damage when the discharge needle enters the underside of beverage pod 100; the use of filter disc 136 may aid in preventing such damage. The “discharge needle” refers to the needle that pierces beverage pod 100 in the process of use of beverage pod 100 in making a beverage. A “filter disc” is a stiff, circular piece of material that is used to filter various fluids. The use of filter disc 136 here may allow for the passage of liquid while preventing the passage of beverage materials that may make it through the preformed filter material 128 adhered to at least an interior surface of shell 108. In an embodiment, filter disc 136 may include materials such as fiber, granular beds, woven fabrics, and / or metal screens. Furthermore, filter discs 132 may be embodied in a circular, oval, square, and / or similar shape. The size and shape may directly relate to the size and shape of beverage pod 100 and specific placement of filter disc 136. Placement of filter disc 136 may be located at the most distant point from the opening of cavity 104 of beverage pod 100. The most distant point may further be described as the floor of cavity 104 of beverage pod 100. Alternatively, placement of filter disc 136 may position filter disc 136 up off the floor, wherein there is space between the floor of cavity 104 and the start of where filter disc 136 may rest within cavity 104. This space between the floor of cavity 104 and the start of filter disc 136 may depend on the beverage material weight being inserted into beverage pod 100. For example, and without limitation, a beverage material that requires more room within cavity 104 may require a larger space between the floor and the start of filter disc 136. Lastly, in an embodiment, filter mechanism 124 may include one or more filter discs 136. In such an embodiment, the first filter disc 136 may be placed nearer to the floor of beverage pod 100, wherein the second filter disc 136 may be placed nearer to the opening of beverage pod 100.

[0030] Continuing the reference FIG. 1, in some embodiments, filter mechanism 124 may be adhered to an interior surface of shell 108 with a frangible seal. This may be accomplished through various manufacturing processes, which may be accomplished without limitation, as disclosed in U.S. application Ser. No. 18 / 599,862, filed Mar. 8, 2024 and entitled “HIGHLY RECYCLABLE BEVERAGE PODS AND METHOD OF MANUFACTURE” the entirety of which is incorporated herein by reference. Further, filter mechanism 124 may be adhered to the bottom edge of the interior surface of shell 108. In one or more embodiments, adherence may be in one or more areas. For example, and without limitation, adhering strips, dots, and / or the like may be used to adhere filter mechanism 124 to shell 108. These strips, dots, and / or the like may be placed about filter mechanism 124 in a pattern and or singularly. In some embodiments, filter mechanism 124 may further include a pull cord and / or a string. In such an embodiment, the pull cord may be attached to the bottom of filter mechanism 124 near the frangible seal adhering filter mechanism 124 to shell 108. This may enable a user to easily break the frangible seal and pull filter mechanism 124 from shell 108 of beverage pod 100.

[0031] In further reference to FIG. 1, in an embodiment, beverage pod 100 may include a beverage material placed within filter mechanism 124. “Beverage material” for the purposes of this disclosure, is a substance that may interact with a fluid to provide a beverage. In some cases, beverage material may include ground coffee beans wherein water may interact with the coffee beans to create coffee. Alternatively, beverage material may include cocoa powder, lemonade powder and / or any additional powder that may be used to create a beverage. In some cases, beverage material may include a concentrated liquid wherein the concentrated liquid may interact with a fluid to provide a less concentrated beverage. In some cases, filling the filter mechanism 124 adhered to the interior of cavity 104 with beverage material, having a headspace atmosphere may include filling beverage pod 100 with ground coffee beans. In some cases, filter mechanism 124 may be configured to allow a liquid to pass through while the beverage material may be held by filter mechanism 124. For example, coffee grounds may be mixed with a liquid wherein coffee may seep out of filter mechanism 124 while the coffee grounds are held back by filter mechanism 124. In some embodiments, beverage material may react with a fluid wherein the beverage material may dissolve and pass though filter mechanism 124. Additionally, in some cases, filter mechanism 124 may blanket a surface of shell 108 wherein beverage material may be placed on top of filter mechanism 124. In an embodiment, beverage material may fill cavity 104 of beverage pod 100 and / or alternatively, at least partially fill cavity 104 of beverage pod 100.

[0032] With continued reference to FIG. 1, “headspace atmosphere” for the purposes of this disclosure is any gaseous substance that is situated within and / or above beverage material within beverage pod 100. For example, headspace may include oxygen wherein the oxygen may be situated between and / or on top of the beverage material. The degradation of beverage materials and / or ingredients may occur in the presence of oxygen. This degradation may shorten the shelf-life and freshness of beverage materials and their ingredients. Therefore, there may be a need to remove any oxygen within cavity 104 of beverage pod 100 in order to preserve the freshness of the beverage material within cavity 104.

[0033] With continued reference to FIG. 1, in an embodiment, beverage pod 100 may include airtight lid 140. Airtight lid 140 may be configured to prevent beverage material from interacting with the atmosphere exterior to the interior of cavity 104. In some cases, airtight lid 140 may provide for an airtight seal between beverage material and the surrounding atmosphere. In some cases, airtight lid 140 may include aluminum, plastic, foils and / or any combination thereof. For example, and without limitation, airtight lid 140 may include an aluminum foil material and a polymeric coating. In some cases, airtight lid 140 may include a pull cord or a tab wherein a user may grip onto pull cord in order to remove airtight lid 140. In an embodiment, the pull cord or tab may be configured as part of the lid. Alternatively, in an embodiment, the pull cord or tab may be separate from the lid and attached in a manufacturing process. For example, in an embodiment, wherein the pull cord or tab is separate from the lid, the pull cord or tab may be attached with an adhesive and / or through a manufacturing process utilizing multiple polymer layers. In an embodiment, the pull cord or tab may extend across the entire lid through the center, around the edges, and / or in another pattern capable of maintaining its integrity when force is applied. The pull cord or tab may include plastic, paper, metal, foils, and / or alloy components or threads to enhance strength of the tab. Additionally, in an embodiment, the pull cord or tab may be configured to lay flat on the exterior wall of shell 108. This may be accomplished through the application of adhesives. In another embodiment, shell 108 may include a perforation that may be configured to transform into a pull cord or tab when force is applied to it. The pull tab may additionally have the ability to be printed, stamped, and / or the like with images and / or text. Airtight lid 140 material may enable a hermetic seal capable of surviving high altitude distribution as well as allowing easy removal, for example by peeling lid 124 from the pod by the consumer after preparing a beverage. As used in this disclosure, “hermetic” is a complete and airtight lid. Lid 124 material may be a specified combination of a metallic material, and polymeric coatings and / or laminates on the interior or sealing surface. In an embodiment, there may further be an exterior portion to lid 124 configured to display print of some sort. Lid 124 may be sealed / welded / adhered to the aluminum pod. Further, airtight lid 140 may include a frangible seal, without limitation, as disclosed in U.S. application Ser. No. 18 / 606,085, filed Mar. 15, 2024 and entitled “CONTAINER WITH A PEELABLE LID HAVING A FRANGIBLE SEAL AND METHOD OF MANUFACTURE”the entirety of which is incorporated herein by reference.

[0034] Now referring to FIG. 2A-2D, illustrated are multiple exemplary configurations of tabs of filter mechanisms. Filter mechanism 200a is an exemplary illustration of an embodiment configured with a single tab 204a. Although shown as rounded, in some embodiments tabs may be square, pleated, and / or any shape that may fit the configuration of the beverage pod it is placed within. As shown, tab 204a is configured to extend past shoulder 208a. In one or more embodiments, tab 204a may be configured to fold inward as described above in relation to FIG. 1. Filter mechanism 200b illustrates an exemplary illustration of an embodiment configured with an additional tab 204b, wherein the total number of tabs is equal to two. Such an embodiment may be beneficial to a user as the user may pull from both sides of filter mechanism 200b, distributing the force and avoiding spilling the contents. Although shown as rounded, in some embodiments each tab 204b may be square, pleated, and / or any shape that may fit the configuration of the beverage pod it is placed within. As shown, tab 204b may be folded inward, away from shoulder 208b, so as not to interfere with Lid 140 sealing. Filter mechanism 200c is an exemplary illustration of an embodiment configured with three additional tabs 204c, wherein the total number of tabs is equal to four. Although shown as rounded, in some embodiments each tab 204c may be square, pleated, and / or any shape that may fit the configuration of the beverage pod it is placed within. As shown, tab 204c may be folded inward, away from shoulder 208c so as not to interfere with Lid 140 sealing. Filter mechanism 200d is an exemplary illustration of an embodiment configured in a ring formation. As shown, tab 204d may be configured to lay atop beverage material as described in relation to FIG. 1. Though rings may bring to mind a circular shape, such an embodiment may additionally include a square, oval, and / or the like to fit the shape of the beverage pod filter mechanism 200d is placed within.

[0035] Now referring to FIGS. 3A and 3B and 3C, illustrated is an exemplary filter mechanism configuration wherein the tab includes a plurality of cutouts defining a loop, thereby enabling a user to pull the loop defined by the plurality of cutouts. Such an embodiment including a plurality of cutouts defining a loop may otherwise be described as a handle configuration. Filter mechanism 300a illustrates a side view of the embodiment, which may include one or the other of 300b and / or 300c. Plurality of cutouts 304a may include hemispheres, slits, and / or the like. The handle configuration 308a may be attached to a ring portion of the tab which may be sealed to the shoulder of the beverage pod. Handle configuration 308a may be folded down at a pivot point 312a, so that a beverage pod may be sealed without interference from any embodiment of filter mechanism, including filter mechanism 300a. Filter mechanism 300b illustrates an embodiment including two handle configurations 308b on opposite sides of filter mechanism 300b. Handle configuration 308b may be attached to a ring portion 312b of the tab. Alternatively, 300c illustrates an embodiment including one handle configuration 308c. In said embodiment, handle 308c may be attached at a first point on filter mechanism 300c and a second point on filter mechanism 300c. The first and second point on filter mechanism 300c may include a ring portion 3012c of the tab. Further, in some embodiments, filter mechanism 300a, including 300b and 300c, may include a cinching mechanism. This may be accomplished by running a cord and / or a string through a channel sewn into the top edge of filter mechanism 300a. The present embodiments illustrate specific orientations; however, attachments may include varying placements based on preference and or in lieu of manufacturing processes.

[0036] Now referring to FIG. 4, illustrated is an embodiment of filter mechanism 400, wherein filter mechanism 400 further includes a pull cord 408. Pull cord 408 may be additional material attached at the bottom of formed filter material 404. Further the location of attachment may be placed strategically near the frangible seal of formed filter material 404 to the shell of the beverage pod. Pull cord 408 may include the same material as formed filter material 404 and / or may include differing material to enable a user to easily identify pull cord 408. Pull cord 408 may be used in any embodiment of filter mechanism as discussed throughout this disclosure, as it is in addition to the one or more tabs as described throughout this disclosure and not in place of. In one or more embodiments, utilizing pull cord 408 enables a user to easily remove the entirety of filter mechanism 400. This is so, at least in part due to the location of pull cord 408. For example, because pull cord 408 is located near the frangible seal of formed filter material 404, when a user pulls on a tab as well as pull cord 408, the user may easily remove filter mechanism 400 and its contents without creating a mess or needing additional tools.

[0037] Now referring to FIG. 5, illustrated is an embodiment of filter mechanism 500, wherein filter mechanism 500 includes a cinching mechanism. Filter mechanism 500 may include a tab 504 that is connected to a string or thread 508. Thread 508 may be enclosed within a channel, except where attached to tab 504. When a user pulls tab 504 it pull thread 508 through the channel closing filter mechanism 500. This may be particularly useful when trying to avoid messes.

[0038] Now referring to FIG. 6, a flow diagram of an exemplary method 600 of manufacture for a recyclable beverage pod having a specialized filter mechanism is illustrated.

[0039] The method 600 of manufacture for recyclable beverage pods having a specialized filter mechanism may include a step 605 of providing a beverage pod having a cavity comprised of a shell. This may be implemented as described with reference to FIGS. 1-5. Further, method 600 of manufacture for recyclable beverage pods having a specialized filter mechanism may include a step 610 of placing a filter disc into the cavity of the beverage pod. This may be implemented as described with reference to FIGS. 1-6. Method 600 of manufacture for recyclable beverage pods having a specialized filter mechanism may further include a step 615 of adhering a formed filter material within the cavity of the beverage pod. This may be implemented as described with reference to FIGS. 1-5. Furthermore, method 600 of manufacture for recyclable beverage pods having a specialized filter mechanism may include a step 620 of filling the formed filter material adhered to the interior of the cavity with beverage material, having a headspace atmosphere. This may be implemented as described with reference to FIGS. 1-5. Method 600 of manufacture for recyclable beverage pods having a specialized filter mechanism may include a step 625 of modifying the headspace atmosphere within the cavity. This may be implemented as described with reference to FIGS. 1-5. Method 700 of manufacture for recyclable beverage pods having a specialized filter mechanism may include a step for folding one or more tabs inward, so that the one or more tabs do not interfere with the lid sealing process. This may be implemented as described in relation to FIGS. 1-5. Further method 600 of manufacture for recyclable beverage pods having a specialized filter mechanism may include a step 630 of sealing the cavity with an airtight lid. Furthermore, method 600 of manufacture for recyclable beverage pods having a specialized filter mechanism may include a step 635 of discharging the beverage pod into a secondary packaging operation. This may be implemented as described with reference to FIGS. 1-5. Furthermore, wherein the method of manufacture 600 requires de-nesting of beverage pods, method 600 may further include providing a plurality of beverage pods, and de-nesting one or more beverage pods from the plurality of beverage pods. Lastly, wherein method 600 further requires filter material forming, method 600 may include forming filter material and press-forming the formed filter material. Beverage materials are contained in formed beverage pods having an internally attached porous pre-formed filter material which enables beverages to be prepared in a beverage making appliance, for example, and without limitation a single-serving coffee maker, and certain solids retained such as, without limitation coffee grounds. The beverage pods may be hermetically sealed with a peelable lid material, making it easy for the consumer to remove the beverage materials and recycle the beverage pods.

[0040] Still referring to FIG. 6, method of manufacture for recyclable beverage pods having a specialized filter mechanism 600 may in some cases produce beverage pods configured for a single serving of a given beverage. Other embodiments may include beverage pods configured for a multi serving of a given beverage. Furthermore, in an embodiment, and without limitation, method 600 may produce recyclable beverage pods having a specialized filter mechanism configured for use in a low-pressure beverage making appliance. “Low-pressure,” as used in this disclosure, is defined as 1 to 2 Bar atmospheric pressure. Low-pressure is compared to high-pressure appliances, such as espresso machines, which may include 9 Bar or above of atmospheric pressure.

[0041] Exemplary embodiments have been disclosed above and illustrated in the accompanying drawings. It will be understood by those skilled in the art that various changes, omissions and additions may be made to that which is specifically disclosed herein without departing from the spirit and scope of the present invention.

Claims

1. A beverage pod comprising:a cavity comprising a shell, wherein the shell comprises one or more detents configured to interlock with one or more beverage pods, wherein the one or detents comprises circumferential beads to stack the one or more beverage pods on top and within one another, wherein the circumferential beads are in diagonal pattern in relation to a lip of a beverage pod and configured to produce an audible confirmation indicating that at least two beverage pods have been locked together;a filter mechanism, wherein:the filter mechanism comprises a formed filter material comprising a tab, wherein the formed filter material is composed of at least 20 percent of a non-woven flashspun high-density polyethylene; andthe formed filter material is adhered to an interior surface of the shell using a frangible seal;a beverage material placed within the filter mechanism; andan airtight lid sealing the filter mechanism and the beverage material within the cavity.

2. The beverage pod of claim 1, wherein the shell is comprised of a metal material.

3. The beverage pod of claim 1, wherein the shell is comprised of an alloy material.

4. (canceled)5. The beverage pod of claim 1, wherein the formed filter material is comprised of 80 percent cellulose fibers.

6. The beverage pod of claim 1, wherein the formed filter material comprising the tab further comprises one or more additional tabs.

7. The beverage pod of claim 1, wherein the tab of the formed filter material is configured to fold flat within the shell when the airtight lid is attached to the shell of the beverage pod.

8. The beverage pod of claim 7, wherein:the tab extends past a shoulder, wherein the shoulder is a pivot point; andthe tab is configured to fold inward along the pivot point.

9. The beverage pod of claim 1, wherein the shell further comprises:a shoulder disposed within an interior of the shell;wherein the tab comprises a ring tab; andthe ring tab is configured to lay atop the beverage material.

10. The beverage pod of claim 9, wherein the filter mechanism is adhered to the shoulder.

11. The beverage pod of claim 1, wherein the filter mechanism comprises a pouch configuration, wherein the pouch configuration is sealed with the beverage material within.

12. The beverage pod of claim 1, wherein the filter mechanism further comprises a cinching mechanism.

13. The beverage pod of claim 1, wherein the tab comprises an undulating border, thereby enabling a user to identify a location of the tab.

14. The beverage pod of claim 1, wherein the tab comprises a plurality of cutouts defining a loop, thereby enabling a user to pull the loop defined by the plurality of cutouts.

15. The beverage pod of claim 1, wherein the tab comprises two ends, wherein a first end is attached to the filter mechanism at a first point and a second end is attached diametrically opposite of the first point.

16. The beverage pod of claim 1, wherein the filter mechanism is adhered to an interior surface of the shell using a frangible seal.

17. The beverage pod of claim 16, wherein the filter mechanism further comprises a pull cord attached to a bottom of the filter mechanism by the frangible seal.

18. The beverage pod of claim 1, wherein the beverage pod further comprises a filter disc placed within the cavity and configured to suspend the filter mechanism above a bottom of an interior of the shell.

19. The beverage pod of claim 1, wherein the airtight lid comprises a peelable lid.

20. The beverage pod of claim 1, wherein the airtight lid is comprised of an aluminum foil material and a polymeric coating.

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