WO2014044278A1

WO2014044278A1 - A method of producing a disposable brewing device, a disposable brewing device and a method of forming an exit opening in a disposable brewing device

Info

Publication number: WO2014044278A1
Application number: PCT/DK2012/050355
Authority: WO
Inventors: Ulrik SKOVGAARD RASMUSSEN
Original assignee: Columbus E. Aps
Priority date: 2012-09-24
Filing date: 2012-09-24
Publication date: 2014-03-27

Abstract

Disclosed is a method of producing a disposable brewing device (1). The method comprises the steps of •. providing a sheet material (10), •. providing an exit opening blocking device (16), •. positioning said exit opening blocking device (16) between a first edge (17) of a first side sheet (22) of the sheet material (10) and a second edge (18) of a second side sheet (23) of the sheet material (10), •. welding the first edge (17) and the second edge (18) together by means of a welding (12) extending at least partly across the exit opening blocking device (16) to form a fluid-impermeable barrier, • · inserting aroma material (4) into a compartment (2) of the brewing device (1), and • · closing the brewing device (1). A method for forming an exit opening (8) in a disposable brewing device (1), a disposable brewing device (1) comprising aroma material (4) and use of a disposable brewing device (1) are also disclosed.

Description

A METHOD OF PRODUCING A DISPOSABLE BREWING DEVICE, A DISPOSABLE BREWING DEVICE AND A METHOD OF FORMING AN EXIT OPENING IN A DISPOSABLE BREWING

DEVICE Field of the invention

The invention relates to a method of producing a disposable brewing device, a method for forming an exit opening in a disposable brewing device so that a brewed liquid inside the brewing device may be poured out of the brewing device through the exit opening. The invention further relates to a disposable brewing device and use of a disposable brewing device.

Background of the invention

From WO 2005/105604 Al it is known to form a self-standing disposable brewing device from film layers welded together. E.g. ground coffee is arranged in a filter device inside the brewing device, so that when hot water is introduced into the device through the top opening, the water will pass down through the ground coffee and the filter device, and down to a bottom compartment. An exit opening can be formed at the top of the device by folding a top flap so that the brewed coffee may be poured out of the brewing device through this opening. However, in this configuration the shape of this exit opening is defined by the user, hereby making it difficult to ensure a desired size of the exit opening and to ensure that the exit opening is substantially drip free. From WO 2005/105604 Al it is therefore also known to cut off a corner of a fully closed brewing device by a pair of scissors to establish the exit opening. But the use of external tools to open the brewing device is not desirable.

From WO 2005/105606 Al it is therefore known to provide the disposable brewing device with a threaded exit hole in the side of the bag to be corked or provide with a tap. But this exit opening arrangement is both complicated to manufacture and use and it is expensive. From WO 2005/105606 Al it is therefore also known to provide the brewing device with a perforated tear line so that a predefined part (typically a corner) of the device can be torn off to establish a well-defined exit opening. But to ensure that it is fairly easy to tear off the corner and to ensure that the device only tears along the path of the perforations, the perforations have to extend all the way through the brewing device hereby breaking the sealing of the aroma material inside the device, which entails that further outer sealing is required.

An object of the invention is therefore to provide for an advantageous and cost- efficient method for producing and opening a disposable brewing device and a disposable brewing device having an advantageous and cost-efficient exit opening arrangement.

The invention

The invention provides for a method of producing a disposable brewing device. The method comprises the steps of providing a sheet material,

providing an exit opening blocking device,

positioning said exit opening blocking device between a first edge of a first side sheet of the sheet material and a second edge of a second side sheet of the sheet material,

welding the first edge and the second edge together by means of a welding extending at least partly across the exit opening blocking device to form a fluid-impermeable barrier,

inserting aroma material into a compartment of the brewing device, and · closing the brewing device.

Placing the exit opening blocking device between the two sheet edges before the edges are welded is advantageous in that the exit opening blocking device thereby can be attached to the edges during the welding of the edges, hereby simplifying the manufacturing process and reducing time and cost. Furthermore, by simply placing the exit opening blocking device in the path of a welding, the exit opening actually does not exist until the exit opening blocking device is removed and thereby breaks the welding, hereby providing an advantageous and simple brewing device design by which a defined exit opening very simply can be established.

Furthermore, this process enables a more environmentally friendly exit opening blocking device as the amount of material used is minimal and the method also provides a simple way for forming an aroma tight sealing of the exit opening. Furthermore, connecting the sheet material parts by means of welding is

advantageous in that it enables that the connection can be made without the use of further material - such as adhesive, staples or other - hereby enabling a simple, fast and inexpensive manufacturing process that furthermore is environmentally friendly. It should be noted that the term "a first edge of a first side sheet of said sheet material and a second edge of a second side sheet of said sheet materiaF does not exclude that the first side sheet and the second side sheet are connected e.g. along an edge fold. I.e. the two side sheets could be formed as two separate sheets of the sheet material but they could also be formed from a single sheet being folded to form a first side sheet and a second side sheet wherein between other parts or devices - such as the exit opening blocking device - can be arranged.

In an aspect of the invention, said welding forms part of an outer edge welding around at least a part of the outer edge of said brewing device.

Forming the exit opening blocking device - and thereby the exit opening - in an outer edge welding of the brewing device is advantageous in that access to the interior of the device can hereby easily be established. In an aspect of the invention, said first side sheet forms at least part of a first side of an outer compartment and said second side sheet forms at least part of a second side of said outer compartment of said brewing device. In an aspect of the invention, said method further comprises positioning liquid- permeable filter material between said first side sheet and said second side sheet to form at least one inner compartment between said side sheets.

In an aspect of the invention, said method further comprises welding said liquid- permeable filter material to said first side sheet and said second side sheet to suspend said at least one inner compartment between said side sheets.

Forming and suspending an inner compartment formed by a filter material inside the brewing device is advantageous in that it enables that fragments may be filtered out of the liquid passing through the device during a brewing process.

In an aspect of the invention, said aroma material is inserted into said at least one inner compartment. Placing the aroma material in the inner compartment is advantageous in that given the suspended state, gravity will pull the introduced liquid down through the aroma material and due to the filtering effect of the liquid-permeable filter material the aroma material stays in the inner compartment while the brewed liquid can continue through the device.

In an aspect of the invention, said method further comprises positioning a bottom sheet material between said first side sheet and said second side sheet to form a bottom of said brewing device. In an aspect of the invention, said method further comprises welding said bottom sheet material to said first side sheet and said second side sheet.

Forming a bottom by means of a bottom sheet material welded to the side sheets is advantageous in that it provides the device with a wide and solid base for securely supporting the device in a standing-up position, hereby avoiding the need for extra equipment for maintaining the brewing device in an upright position at least during use for brewing. In an aspect of the invention, said method further comprises attaching a re-sealing device in or at an entrance opening of said brewing device, wherein said entrance opening is arranged at an upper edge of said brewing device.

Providing a re-sealable entrance opening at the upper edge of the brewing device is advantageous in that it enables that gravity can be used during the brewing process for pulling the liquid down through the device.

Making the entrance opening re-sealable is advantageous in that it ensures that the liquid in the device do not overflow through the entrance opening e.g. when liquid is poured out of the exit opening, it improves the safety of the product by preventing large amounts of hot liquid from exiting the device through the entrance opening if the device is accidently toppled during use and it enables a more controlled environment inside the brewing device before and during the brewing process. In an aspect of the invention, said exit opening blocking device comprises a pull- strip.

Forming the exit opening blocking device as a pull-strip is advantageous in that a pull-strip is a simple, inexpensive and environmentally desirable way of sealing a disposable product. Furthermore, by using a pull-strip as exit opening blocking device, substantially the entire disposable brewing device can be made from sheet material welded together, hereby providing a simple and inexpensive brewing device that is easy to

manufacture.

Even further, the flat nature of sheet material enables that during storage, transport etc. the brewing device can be formed very thin hereby enabling that many devices can be stored, transported etc. in a relatively small space hereby reducing cost of transportation, storage etc. And given the flexible nature of the sheet material the device will have no problem in expanding and adapting to the liquid during the brewing process.

Thus, an advantageous disposable brewing device is achieved by forming the device substantially entirely of sheet material parts that are substantially welded together.

In an aspect of the invention, said pull-strip is folded or placed in a double layer configuration while or before being positioned between said two sheet edges. Placing the pull-strip in a double layer configuration is advantageous in that it enables that the pull-strips resistance towards being ripped off can be better controlled by forming the pull-strip from a material having different properties regarding melting point and other in relation to the adjoining sheet material.

Furthermore, given that the middle welding between the two layers of strip material will not weld as tight as between the sheet material and the strip material the pull- strip will have a natural tendency to open between the two layer of strip material, hereby ensuring a more defined exit opening and ensuring that the strip material can stay attached to the brewing device even after the exit opening has been established. This could be advantageous in it will ensure that the entire disposable brewing device - including pull-strips - can be discarded in a single operation. The double layer pull-strip hereby forms an aroma tight blocking device that is also an easily removable exit opening blocking device. It should be noted that the term "double layer configuration" in this context means that the pull-strip could be formed by folding a single strip into a double layer pull- strip or the pull-strip could be formed by two individual pieces of strip being placed on top of each other to form a double layer pull-strip.

In an aspect of the invention, said exit opening blocking device is positioned so that it extends beyond the outer perimeter of said first side sheet and said second side sheet. Placing the exit opening blocking device so that it protrudes from the device and extends beyond the outer perimeter of the device is advantageous in that it facilitates easy access to the pull-strip making it easy to identify it and to get a strong hold of it before pulling it off. In an aspect of the invention, said exit opening blocking device is positioned between and welded to said first edge of said first side sheet and said second edge of said second side sheet so that when said exit opening blocking device is removed from said brewing device, said welding is broken and an exit opening of said brewing container is formed in said brewing device, through which a brewed liquid may be poured out of said brewing device.

In an aspect of the invention, said closing of said brewing device comprises forming a breakable top sealing along at least part of an upper edge of said brewing device. Providing the brewing device with a breakable top sealing along an upper edge is advantageous in that it hereby is possible to also seal the entrance opening and thereby ensure a more controlled environment inside the brewing device until use.

In an aspect of the invention, said first edge is welded to said second edge and said exit opening blocking device in a single welding process.

Welding the edges together and to the exit opening blocking device in a single welding process is advantageous in that it provides for a simple and fast

manufacturing process.

In an aspect of the invention, said first edge and said second edge are welded to form an exit opening which is blocked by said exit opening blocking device.

In an aspect of the invention, said exit opening enables a fluid passage from the interior of said brewing device to the exterior of said brewing device.

In an aspect of the invention, said exit opening enables a fluid passage from an inner compartment inside said brewing device to the exterior of said brewing device.

Arranging the exit opening so that it establishes a fluid passage from the inner compartment is advantageous in that the liquid then will have to take a pre-defined route through the device - i.e. through the aroma material in the inner compartment and down to a brewing compartment being formed inside the outer compartment and then out of the device through the exit opening to enable a controlled brewing process.

In an aspect of the invention, said disposable brewing device is a brewing device according to any of brewing devices mentioned below. The invention also provides for a method for forming an exit opening in a disposable brewing device so that a brewed liquid inside the brewing device may be poured out of the brewing device through the exit opening. The method comprises the steps of · grabbing a tight hold of at least one free end of an exit opening blocking device being placed between two sheets of sheet material forming at least part of an outer compartment of the brewing device, the exit opening blocking device extending in the path of an edge welding of the brewing device, and

· pulling the exit opening blocking device at least partly off of the brewing device to break the edge welding, thereby forming the exit opening.

Creating the exit opening in a disposable brewing device by simply pulling an exit opening blocking device of off the device is advantageous in that it provides for a simple and inexpensive opening technique which can be performed without the use of additional equipment.

In an aspect of the invention, at least a part of said free end of said exit opening blocking device extends beyond the outer perimeter of said outer compartment thereby making it easier to grab a tight hold the free end.

In an aspect of the invention, said exit opening blocking device is welded to said two sheets of sheet material. In an aspect of the invention, said exit opening blocking device is a pull-strip.

In an aspect of the invention, said method is a method for forming an exit opening in a disposable brewing device produced by a method according to any of the previously mentioned methods. Furthermore, the invention provides for a disposable brewing device comprising aroma material. The brewing device comprises a first side sheet and a second side sheet being welded together along an edge of the first side sheet and the second side sheet to form at least part of an outer compartment of the brewing device. An exit opening blocking device comprising a pull-strip is arranged between the first side sheet and the second side sheet and wherein the exit opening blocking device extends in the path of the edge welding.

Making the pull-strip extend in the path of the edge welding is advantageous in that it hereby is easy to manufacture the device, in that the pull-strip can be attached by means of the welding attaching the two side sheets together. Furthermore, a pull- strip is a simple and inexpensive device being particularly suited for a disposable device.

Even further, a pull-strip enables that the entire device can be formed by welded sheet material hereby providing a simple, inexpensive and compact brewing device.

As previously mentioned it should be noted that the term "The brewing device comprises a first side sheet and a second side sheet... " does not exclude that the first side sheet and the second side sheet are connected e.g. along an edge fold. I.e. the two side sheets could be formed as two separate sheets of the sheet material but they could also be formed from a single sheet being folded to form a first side sheet and a second side sheet wherein between other parts or devices - such as the exit opening blocking device - can be arranged. In an aspect of the invention, said exit opening blocking device blocks an exit opening of said outer compartment, so that when said exit opening blocking device is removed a brewed liquid may be poured out of said outer compartment through said exit opening. In an aspect of the invention, at least one inner compartment is suspended inside said outer compartment.

A better brewing quality is achieved if the added liquid can pass through the aroma material in the inner compartment instead of merely getting in contact with the aroma material - as with traditional tea bags. Thus, by suspending the inner compartment comprising the aroma material inside the brewing container gravity will pull the liquid through the aroma material and down into a brewing container below/around the inner compartment, hereby ensuring a simple and efficient brewing device.

In an aspect of the invention, said at least one inner compartment is formed at least partly by a liquid-permeable filter material.

Forming the inner compartment by a liquid-permeable filter material is advantageous in that it enables that the aroma material in the inner compartment is filtered out of the passing liquid, hereby ensuring a more controlled brewing process.

In an aspect of the invention, said aroma material is located in said at least one inner compartment.

In an aspect of the invention, said brewing device comprises an entrance opening for introducing liquid into said brewing device.

In an aspect of the invention, said entrance opening extends substantially the entire length of the upper edge of said brewing device.

To ensure that it is fairly easy to fill the necessary amount of liquid into the brewing device without spilling, it is advantageous that the entrance opening is as large as possible and therefore is made to extend substantially the entire width of the upper edge of the brewing device. Furthermore, it ensures that an adjacent or abutting edge welding is not torn when the entrance opening is opened.

In an aspect of the invention, said exit opening is arranged at said entrance opening.

It is obviously advantageous to place the entrance opening at the top of the brewing device to ensure that the liquid can easily be poured into the brewing device and to ensure that the liquid does not overflow even through the entrance opening is not sealed. But it is also advantageous to position the exit opening at the top of the device near the entrance opening to ensure that the brewed liquid does not overflow through the exit opening e.g. in case an exit opening blocking device is not present and it enables that the brewed liquid can be removed controllably from the brewing device simply by tilting the brewing device to lower the exit opening in relation to the level of the brewed liquid inside the device and thereby pour brewed liquid out of the exit opening in a controlled manner.

In an aspect of the invention, said first side sheet and said second side sheet are formed by a flexible film material. Forming the first side sheet and the second side sheet from a flexible film material is advantageous in that it enables that the shape of the brewing device can change and thereby adapt to liquid being pour into the device. The device can thereby be formed compact and easy to pack and store while at the same time being able to contain a relatively large amount of liquid due to the flexible quality of the film material.

In an aspect of the invention, said brewing device is formed as a stand-up pouch, having a contact face adapted for maintaining the longitudinal extent of said brewing device in a substantial vertical stand-up position at least during use for brewing. Forming the brewing container as a stand-up pouch e.g. by making the bottom of the device comprises a shape sealed fold to form a contact face supporting the device, is advantageous in that it enables that the device is self-standing and hence no equipment is needed to support the brewing device, as the device stands by itself. The shape of the contact face - e.g. formed by a weld of the bottom fold - significantly affects the shape of the brewing container when filled with liquid, which means that the brewing container during use may attain e.g. a circular-, oval-, or rectangular-like bottom form. In an aspect of the invention, said at least one outer compartment being formed at least partly by a film material to be expandable from a non-expanded state when filled with liquid.

Forming the outer compartment from a material which allows that the outer compartment may expand from a non-expanded state when filled with liquid is advantageous in that the non-expanded brewing device is less space consuming and thereby easier to store before use. Furthermore, the expandable feature enables the device to have specific qualities in non-expanded shape - such as little total volume, flat configuration (which makes it easy to store and pack) - and in expanded state - such as specific ducts forming, a contact face forming at the bottom allowing the device to be self-standing in a vertical position etc.

In an aspect of the invention, said aroma material comprises roast and/or ground coffee, instant coffee, tea, milk powder, herb, fruit, meat, chocolate powder, vegetables, grains or any combination thereof or any other materials which comprises or provides flavour or aroma or other functionalities.

Other functionalities than flavour or aroma may for example be colour, consistency, energy etc. The beverages made by the brewing device may for example be coffee, espresso, latte, mocha, tea, iced drinks, hot chocolate, blended drinks, fruit juices or any other edible or drinkable fluids. In an aspect of the invention, said at least one outer compartment is at least partly formed by a transparent or translucent material.

Forming the outer compartment at least partly by a transparent or translucent material is advantageous in that it hereby is possible to more precisely dose the liquid into the device without the aid of measuring devices and it is possible to visually control and/or observe the brewing process. The storage capabilities i.e. shelf life of the brewing device before use may be reduced, as a translucent material is obviously not light tight, but a sealing wrapped around the brewing container may solve this problem.

The coating of an at least partly translucent outer compartment may comprise ceramic materials such as aluminium oxides, zirconium oxides, glasses based on silicium oxide or other coating materials such as ethylene vinyl alcohol (EvOH) and combinations thereof.

In an aspect of the invention, said exit opening blocking device extends through a part of said edge welding.

In an aspect of the invention, said disposable brewing device is produced by a method according to any of the previously mentioned production methods.

The invention also provides for use of a disposable brewing device according to any of the previously described brewing devices for brewing of a beverage.

Figures The invention will be described in the following with reference to the figures in which illustrate a prior art disposable brewing device, as seen from the side, illustrate a prior art disposable brewing device, as seen from the front, illustrates a cross-section of the brewing device of fig. 1 at the line II-II, as seen from the front, illustrates a cross-section of the brewing device of fig. 1 at the line III-III, as seen from the front, illustrates a cross-section of the brewing device of fig. 1 at the line IV-IV, as seen from the front, illustrate the brewing device of fig. 1 being opened, as seen in perspective, illustrates the brewing device of fig. 1 being filled with a liquid, as seen in perspective, fig. 8 illustrates the brewing device of fig. 1, wherein the entrance opening is being re-sealed, as seen in perspective, fig. 9 illustrates the brewing device of fig. 1 pouring a brewed liquid, as seen in perspective, illustrates an embodiment of a brewing device with an exit opening blocking device according to the invention, as seen from the side, illustrates a series of connected brewing devices during a manufacturing process, as seen from the side, fig. 12-14 illustrate the opening of a brewing device compri

double layer pull-strip, as seen in perspective, fig. 15-17 illustrate the opening of a brewing device comprising a folded pull-strip, as seen in perspective, fig. 18-20 illustrate the opening of a brewing device comprising a single layer pull-strip, as seen in perspective, and fig. 21-25 illustrate the production of a brewing device comprising a double layer pull-strip, as seen in perspective.

Detailed description of the prior art

For reasons of explanation, parts of the brewing device of fig. 1 and fig. 6-9 are shown as partly transparent. Fig. 1 and 2 illustrates a front view and a side view, respectively, of a prior art brewing device 1.

The brewing device 1 comprises an outer compartment 5 which in this embodiment also forms a brewing container 6. Sheet materials 22, 23, a bottom welding 26, outer edge welding 12 and a top sealing 28 at the entrance opening 3 collectively define the outer brewing compartment. The sheet material 22, 23 furthermore forms a handle 27. Inner compartment 2 is suspended inside the outer compartment 5 and it comprises an entrance opening 3 with a top sealing or closing, e.g. a flap formed by a sheet portion. The top closing 28 is preferably formed with an adhesive for the purpose of closing the bag when liquid has been poured or injected into the device 1.

At the top of the inner compartment 2 the sheet materials 22, 23 are joined in a peelable sealing, and above the sealing a part of the sheet material 22, 23 forms a clutch-flap. A bottom sheet material 30, see also the figs. 3-5, forms a lower part of the outer compartment 5 and the brewing container and the bottom sheet material 30 is laminated to the side welding 12 and is formed by the continuous lamination. The lower arrangement provides a reinforced self-standing arrangement when the outer compartment 5 has been filled at least partly with liquid. Furthermore the brewing device 1 comprises an inner compartment 2 defined by a filter material 31 and welded to the outer compartment 5 defining sheets 22, 23. The inner compartment 2 comprises an aroma material 4, illustrated in figs. 3-5.

Evidently, the fastening of the inner compartment 2 to the outer compartment 5 may be performed in several different ways, e.g. by welding, heat lamination, gluing, etc. and the fastening points may be discrete or continuous, e.g. one or more of the edge welding 12.

The illustrated filter material 31 comprises a polymer film comprising a number of discrete holes of an appropriate size obtained e.g. by stamping. The sizes of the holes may be adjusted to the desired filter function with respect to the applied aroma material 4.

In figs. 3-5, three different cross-sections of the expanded disposable brewing device of fig. 1 are showed at the lines II-II, III-III and IV-IV of fig. 1 respectively. Fig. 3 illustrates a cross-section at the line II-II of the brewing device 1. The illustrated brewing device 1 basically comprises two compartments 2, 5 as described above, namely an inner compartment 2 formed by a filter material 31 located within an outer compartment 5 basically formed by the sheets 22, 23 and 30 by the above described gathering, e.g. welding. The inner compartment 2 comprises an aroma material 4. The above-described continuous lamination of the bottom sheet material 30 to the sheets 22, 23 forms a part of a contact face 14 at the bottom of the brewing device 1, which may ensure that the brewing device 1 is self-standing when at least the outer compartment 5 is at least partly filled with liquid.

Fig. 4 illustrates a cross-section at the line III-III of the unfolded brewing device 1 of fig. 2 and fig. 3 at a cross-section a little closer to the line IV-IV of fig. 1. It is noted that the distance between the inside walls at the bottom of the outer compartment 3 is increased when compared to the cross-section of fig. 3.

Fig. 5 illustrates a cross-section of the line IV-IV of the unfolded brewing device 1 of fig. 2-4 in the midst of the brewing device 1 at line IV-IV. It is noted that the distance between the inside walls at the bottom of the outer compartment 5 is increased when compared to the cross-section of fig. 4.

The sheets 22, 23 and the bottom sheet material 30 may be formed by one single folded sheet. This sheet may comprise a lower arrangement defining welding corresponding to the above described sheet 22, 23 and the bottom sheet material 30 gathering welding 12, 26.

The brewing container materials comprising sheet materials 22, 23 and 30 combined with welding 12 and 26 and the top sealing 28 collectively form an outer sealing of the brewing device 1. This outer sealing may effectively form a barrier for gasses, moisture, aroma and other matters so that diffusion in and out of the brewing container 1 is prevented. Thus, the aroma material 4 contained in the brewing container is hereby protected until the top sealing 28 is broken.

Fig. 6-9 illustrates the process of using an aroma material 4 containing brewing device 1 as described in fig. 1-5. According to the illustrated embodiment the aroma material 4 comprises coffee grounds.

In fig. 6 the brewing device 1 is initially opened by mechanically stretching the sides in the direction of the arrows A and B. Hereby the top sealing 28 is broken.

Clutching and pulling in the upper flaps may perform the stretching to the sides of arrow A.

The initial step of mechanically stretching to the sides of the arrows B may be omitted as the liquid may perform this task during filling.

In fig. 7 a liquid dispenser such as a kettle pours liquid into the brewing device 1. The liquid, preferably hot, mixes with the coffee grounds 4 and forms a liquid coffee suspension within the inner filter compartment 2. In fig. 8 the top flap 13 is folded in the direction of the arrow A.

When the top flap 13 has been closed, the suspension is now contained within the outer compartment 5 of the brewing device 1 - in the brewing container 6 and maybe partly within the inner compartment 2 depending on the amount of liquid poured into the device 1. The closing of the top flap 13 establishes a closed container having an exit opening 8. Typically, the brewing device should now rest for e.g. 1-20 minutes and when brewing e.g. coffee, preferably 2-7 minutes before the brewing is completed. In fig.9 the brewing has been completed and a user may now, e.g. by means of the handle 27 lift the brewing device 1 and pour the brewed liquid, here coffee, into a cup and the drink is ready for intake.

Detailed description of the invention

For reasons of explanation, at least parts of the brewing devices of figs. 10, 11, 13, 14, 16, 17 and 19-25 are shown as partly transparent.

Fig. 10 illustrates an embodiment of a brewing device 1 with an exit opening blocking device 16 according to the invention, as seen from the side.

In this embodiment the brewing device 1 comprises an outer compartment 5 in which an inner compartment 2 is suspended in and above a brewing container 6.

In this embodiment the inner compartment 2 is formed by a liquid-permeable filter material 31 where the liquid-permeable quality of the filter material 31 is obtained by a perforation of small holes. However in another embodiment the liquid-permeable quality may be obtained by a non-woven fibre material, by woven or non-woven textile, reinforced paper or cardboard or by other means.

The liquid-permeable filter material 31, which is provided with holes, may be described as punctured with a certain density of holes per cm2. In an embodiment of the invention the liquid-permeable filter material 31 is provided with a density of holes in the range of 1 - 30 holes per cm2, preferably 2 - 20 holes per cm2 and most preferably 4 - 12 holes per cm2. In an embodiment of the invention the holes have dimensions in the range of 0.01 mm · 0.01 mm to 2.00 mm · 2.00 mm, preferably 0. lmm · 0.1 mm to 1.0 mm · 1.0 mm, more preferably 0.1mm · 0.1 mm to 0.6 mm · 0.6 mm. The preferred size of the hole is an elongated hole of the size 0.2mm^» 0.4 mm. The shape of the hole may vary from application to application. In an embodiment of the invention the dimension of the holes is adapted to provide a brewing time of approximately 3-6 minutes under atmospheric pressure.

In an embodiment of the invention the inner compartment 2 is made of a material selected from the group of polypropylene, polyethylene, polyesters, polyamides, polyolefines or other polymers.

The inner compartment 2 is formed from a single sheet of filter material 31 which is folded at the middle and the two upper ends are connected to the outer compartment 5 just below the top sealing 28 by means of welding.

The filter material 31 extends in the full width W of the outer compartment 5 and is therefore also connected to the outer compartment 5 along the sides by means of the edge weldings 12.

In this embodiment the brewing device 1 also comprises a liquid impermeable barrier 9 defining one side of the inner compartment 2 and forming an outlet duct 15 of the discharge arrangement 7 alongside the inner compartment 2. In this embodiment the liquid impermeable barrier 9 is formed by a welding extending from the bottom 11 of the inner compartment 2 and substantially all the way up to the entrance opening 3 of the inner compartment 2 at the top edge 25 of the device 1.

During normal use the re-sealable entrance opening 3 would first be opened to break the top sealing 28 and an exit opening 8 would be established by pulling off the exit opening blocking device 16 in the form of the pull-strip 20. A liquid would then be introduced into the inner compartment 2 to mix with the pre-arranged aroma material 4 in the inner compartment 1. As soon as all the liquid has been poured into the device 1 the entrance opening 3 is re-sealed - in this case by means of the zip slider extending all the way across the top edge 25 substantially in the entire width W of the device 1 - to protect the inside of the brewing device 1 from externally imposed foreign objects, to increase the quality of the brewing process (e. g. isolating effect) and to ensure that the device 1 does not overflow, if the device 1 is overturned. A zip slider is a slider comprising flanged interlocking profiles which can easily be engaged and disengaged but as discussed above the re-sealing quality of the entrance opening 3 could be obtained through other means.

Because the inner compartment 2 is suspended inside the outer compartment 5, because the inner compartment 2 is formed by a liquid-permeable filter material 31 and because the brewing device 1 is orientated with the inner compartment 2 facing up, a brewing container 6 is also formed inside the outer compartment 5 - primarily at the bottom of the outer compartment 5 - into which the liquid is pulled by gravity as it seeps through the aroma material 4 in the inner compartment 1.

When most of the liquid has passed through the filter 31 and the aroma material 4, the liquid level in the brewing container 6 is preferably higher than the bottom 11 of the inner compartment 2 so the aroma material 4 will continue to be soaking in the liquid.

After a desired brewing time the brewed liquid in the brewing container 6 can be poured out of the exit opening 8 by grabbing the handle 27 of the device 1 and tilting it so that the liquid runs through the outlet duct 15 and out through the exit opening 8.

When the brewing device 1 is used for making coffee the brewing process may involve that coffee grounds are mixed with water, causing an infusion process during which the coffee grounds and water may interact, which may include that the coffee grounds absorb water and thereafter fall down while giving off aroma to the water and thereby bringing about a coffee beverage. In relation to coffee brewing it is an important feature of the brewing device 1 according to the invention that it enables the user to brew coffee in the traditional way. The traditional brewing implies that no pressure above the atmospheric pressure is needed in order to make the water pass through the liquid-permeable filter material 31. Furthermore the brewing device 1 according to the invention advantageously needs no extra or special equipment to function.

In an embodiment of the invention it may be preferred to equip the brewing device 1 with more than one inner compartment 2. The different compartments 2 may be used for different aroma materials 4, which are to be mixed during brewing. Their separation in different compartments 2 secures that they are not mixed before use.

When the brewing device 1 is packed with aroma material 4 such as ground coffee beans having a tendency to loose aroma when exposed to the surroundings, it is of crucial importance that the device is provided with some sort of outer sealing layer that is tight, especially when the amount of aroma material 4 is relatively small compared to larger coffee packages.

This outer sealing could comprise at least one polymer film, metallized or coated film, EvOH-coating, metal foil, sealant, or combinations thereof.

The sheets 22, 23, 30 forming the outer compartment 5 could also be formed as a multi-layer structure comprising an outside polymer film, an intermediate barrier layer and an inside layer of polymer sealant.

Likewise in an embodiment of the invention a preferred combination of materials for a multi-layer structure, which forms the bottom material 30 of the brewing device 1 or of a separate outer sealing may comprise a similar multi-layer structure, wherein the intermediate metal foil barrier layer is substituted for a barrier layer comprising a polymer film being metallized and coated with e.g. EvOH (ethylene vinyl alcohol). In an embodiment of the invention differences in flexibility of the sidewall material 22, 23 and bottom material 30 of the brewing device 1 are manipulated by substitutions, e.g. as described above, where the substitution of metal foil with a metallized film coated with EvOH may facilitate a more flexible multi-layer material.

Preferably, the disposable brewing device 1 is intended to use with liquid such as water or e.g. alcohol or milk. In the present invention a disposable device 1 is defined as a device 1 intended for one or a few times of use.

In this embodiment of the invention the pull-strip 20 is approximately 20 mm wide to ensure that the pull-strip 20 efficiently blocks the exit opening 8 and to ensure that the pull-strip does not break when being torn off - without having to form the pull- strip 20 so thick that it becomes difficult to weld efficiently - but is another embodiment the pull-strip 20 could be formed both wider and more narrow i.e. it could be formed with a width of approximately 6 mm, 8 mm, 12 mm, 16 mm, 22 mm, 26 mm, 30 mm or wider or the pull-strip 20 could be formed with varying width.

In this embodiment the pull-strip 20 is approximately 112 mm long to ensure that the exit opening has a sufficient and desired size and to ensure that the pull-strip 20 blocks the entire exit opening 8. However, in another embodiment of the invention the pull-strip 20 could be formed shorter or longer such as approximately 60 mm, 80 mm, 100 mm, 120 mm, 140 mm, 160 mm or longer or the strips of a double- or multi-layer configuration could be formed with different length.

Furthermore, it should be noted that the size of the pull-strip 20 could also be dependent on the size of the brewing device 1. In this embodiment the disposable brewing device 1 has a size suitable for brewing approximately two cups of brewed liquid i.e. it is suited for brewing approximately a half litre of liquid, but if the brewing device 1 was larger it could be necessary to make the pull-strip 20 larger and if the brewing device 1 was formed smaller - i.e. suited for brewing only one cup - the pull-strip 20 may be formed smaller.

Fig. 11 illustrates a series of connected brewing devices 1 during a manufacturing process, as seen from the side.

Here three brewing devices 1 are combined in a row as a possible output from a machine manufacturing the brewing device 1, but a much larger number e.g. more than thousand brewing devices 1 can be combined in one row. This eases further handling of the brewing devices 1 e.g. by winding up a number of brewing devices 1 before transport of these to the next step in a production line. In this embodiment the pull-strip 20 is formed entirely from a polymer material, such as Poly - Butyl ene - Peel (PE-PA-PE / PEEL) or Peel PE 30 / PETP 12 / PE 30 or other polymer peelable material. In another embodiment some parts of the pull- strip 20 or the entire pull- strip 20 could be formed by another material such as another plastic material, metal - such as aluminium, iron or stainless steel - or the strip 20 could be reinforced by carbon fibres, glass fibres, natural fibres, by a woven or non-woven textile or any combination thereof.

In one embodiment of the invention the pull-strip 20 is welded in between the inner side of the two layers of sheet material 10 representing the first side sheet material 22 and second side sheet material 23 of the brewing device 1. When pulling to open the discharge arrangement 7, the welding 12 which fasten the pull-strip 20 to the sheet material 10 of the brewing device 1 will break and thereby open the discharge arrangement 7 and establish an exit opening 8. Figs. 12-14 illustrate the opening of a brewing device 1 comprising a double layer pull-strip 20, as seen in perspective.

In this embodiment of the invention at least a part of the free end 21 of the pull-strip 20 extends beyond the outer perimeter of the outer compartment 5 and thereby the brewing device as seen in figs. 12 and 13. Thus, it is easy for a user to grab hold of the free end 21 and pull the pull-strip 20 of off the device 1 to establish an exit opening 8 as disclosed in fig. 14. In this embodiment the pull-strip 20 is formed in a double layer configuration in that the pull-strip 20 is formed from a single strip folded at the bottom, so that the pull- strip 20 comprises two layers in the full extent of the pull- strip 20.

Figs. 15-17 illustrate the opening of a brewing device 1 comprising a folded pull- strip 20, as seen in perspective.

In this embodiment of the invention the pull-strip 20 is formed with varying width and varying length and in this case the double layer configuration is achieved by folding the pull-strip 20 down the middle.

Since the pull-strip 20 extends across the entire extent of the exit opening 8 in this embodiment of the invention, the two pull-strip layers does not necessarily have to be welded to each other to ensure that the exit opening 8 is blocked. Figs. 18-20 illustrate the opening of a brewing device 1 comprising a single layer pull-strip 20, as seen in perspective.

In this embodiment of the invention the pull-strip 20 is formed from a single layer of strip material. During production the pull-strip 20 is placed between the first edge 17 of the first side sheet 22 of the sheet material 10 and the second edge 18 of the second side sheet. Hereafter the first edge 17 and the second edge 18 are joined by means of a welding 12 extending across a part of the pull-strip 20 to form a fluid- impermeable barrier that will block the exit opening 8 until the pull-strip 20 is pulled off.

It should be noted that to open the brewing device 1 the pull-strip 20 does not necessarily have to be pulled completely of off the device 1. In this single layer configuration and the previously disclosed double layer configurations, the pull-strip 20 could be pulled almost of off the device but still be attached at the bottom while still enabling that a sufficiently large exit opening 8 is established. Or the pull-strip 20 could only be loosened at one side along either the first edge 17 or the second edge 18 hereby ensuring that the pull-strip 20 would remain attached along the other side or parts of the other side. Figs. 21-25 illustrate the production of a brewing device 1 comprising a double layer pull-strip 20, as seen in perspective.

In this embodiment of the invention the bottom material 30 have been welded to the side sheets 22, 23 and the inner compartment 2 have been formed inside the outer compartment 2 and welded to the side sheets 22, 23 at least by means of the barrier welding 9. A coil 24 of strip material is arranged above the brewing device 1 and from this coil 24 a suitable length of strip material is cut off - See fig. 21.

Hereafter a positioning tool 29 will fold the strip 20 at the middle (See fig. 22) and drive the strip down in between the first edge 17 of the first side sheet 22 and the second edge 18 of the second side sheet 23 (See fig. 23), where after the positioning tool 29 will retract and leave the folded strip material wedged between the edges 17, 18 of the side sheets 22, 23 (See fig. 24). The edges 17, 18 of the side sheets 22, 23 will now be welded together and the side welding 12 along the front edge will extend into the area of the pull-strip 20 to weld the two layers of strip material to each other and to the side sheets 22, 23 to form an exit opening blocking device 16 that will efficiently block the exit opening 8 of the brewing device 1 until the pull-strip 20 is at least partly removed.

In this embodiment an upper barrier welding 32 is also applied to extend the barrier 9 forming the outlet duct 15. In this embodiment this upper barrier welding 32 also extends in the path of the pull-strip 20 hereby further attaching the pull-strip 20 to the side sheets 22, 23. In another embodiment further welding could be applied somewhere across the area of the pull-strip 20.

In the above described production method the pull-strip 30 is welded to both side sheets 22, 23 in a single welding process. However, in another embodiment of the invention the pull-strip 20 is first welded to the first side sheet 22 where after the second side sheet 23 is placed on top of the first side sheet 22 and the pull-strip 20 and then welded to both. I.e. in this production method the pull-strip 20 is welded to the side sheets 22, 23 in a two-step welding process.

The invention has been exemplified above with reference to specific examples of brewing devices 1, compartments 2, 5, pull-strips 20 and other. However, it should be understood that the invention is not limited to the particular examples described above but may be designed and altered in a multitude of varieties within the scope of the invention as specified in the claims.

List

1. Disposable brewing device

2. Inner compartment

3. Entrance opening

4. Aroma material

5. Outer compartment

6. Brewing container

7. Discharge arrangement

8. Exit opening

9. Barrier

10. Sheet material

11. Bottom of inner compartment

12. Edge welding

13. Top flap

14. Contact face

15. Outlet duct

16. Exit opening blocking device

17. First edge of first side sheet

18. Second edge of second side sheet

19. Re-sealing device

20. Pull- strip

21. Free end of exit opening blocking device

22. First side sheet

23. Second side sheet

24. Coil of strip material

25. Upper edge of brewing device

26. Bottom welding

27. Handle

28. Top sealing 29. Positioning tool

30. Bottom sheet material

31. Filter material

32. Upper barrier welding

H. Longitudinal extent of brewing device

W. Length of upper edge of brewing device

Claims

1. Method of producing a disposable brewing device (1), said method comprising the steps of

• providing a sheet material (10),

• providing an exit opening blocking device (16),

• positioning said exit opening blocking device (16) between a first edge (17) of a first side sheet (22) of said sheet material (10) and a second edge (18) of a second side sheet (23) of said sheet material (10),

• welding said first edge (17) and said second edge (18) together by means of a welding (12) extending at least partly across said exit opening blocking device (16) to form a fluid-impermeable barrier,

• inserting aroma material (4) into a compartment (2) of said brewing device (1), and

• closing said brewing device (1).

2. A method according to claim 1, wherein said welding (12) forms part of an outer edge welding (12) around at least a part of the outer edge of said brewing device (1).

3. A method according to claim 1 or 2, wherein said first side sheet (22) forms at least part of a first side of an outer compartment (5) and said second side sheet (23) forms at least part of a second side of said outer compartment (5) of said brewing device (1).

4. A method according to any of the preceding claims, wherein said method further comprises positioning liquid-permeable filter material (31) between said first side sheet (22) and said second side sheet (23) to form at least one inner compartment (2) between said side sheets (22, 23).

5. A method according to claim 4, wherein said method further comprises welding said liquid-permeable filter material (31) to said first side sheet (22) and said second side sheet (23) to suspend said at least one inner compartment (2) between said side sheets (22, 23).

6. A method according to claim 4 or 5, wherein said aroma material (4) is inserted into said at least one inner compartment (2).

7. A method according to any of the preceding claims, wherein said method further comprises positioning a bottom sheet material (30) between said first side sheet (22) and said second side sheet (23) to form a bottom of said brewing device (1).

8. A method according to any of the preceding claims, wherein said method further comprises welding said bottom sheet material (30) to said first side sheet (22) and said second side sheet (23).

9. A method according to any of the preceding claims, wherein said method further comprises attaching a re-sealing device (19) in or at an entrance opening (3) of said brewing device (1), wherein said entrance opening (3) is arranged at an upper edge (25) of said brewing device (1).

10. A method according to any of the preceding claims, wherein said exit opening blocking device (16) comprises a pull-strip (20).

11. A method according to claim 10, wherein said pull-strip (20) is folded or placed in a double layer configuration while or before being positioned between said two sheet edges (17, 18).

12. A method according to any of the preceding claims, wherein said exit opening blocking device (16) is positioned so that it extends beyond the outer perimeter of said first side sheet (22) and said second side sheet (23).

13. A method according to any of the preceding claims, wherein exit opening blocking device (16) is positioned between and welded to said first edge (17) of said first side sheet (22) and said second edge (18) of said second side sheet (23) so that when said exit opening blocking device (16) is removed from said brewing device (1), said welding (12) is broken and an exit opening (8) of said brewing device (1) is formed in said brewing device (1), through which a brewed liquid may be poured out of said brewing device (1).

14. A method according to any of the preceding claims, wherein said closing of said brewing device (1) comprises forming a breakable top sealing (28) along at least part of an upper edge (25) of said brewing device (1).

15. A method according to any of the preceding claims, wherein said first edge (17) is welded to said second edge (18) and said exit opening blocking device (16) in a single welding process.

16. A method according to any of the preceding claims, wherein said first edge (17) and said second edge (18) are welded to form an exit opening (8) which is blocked by said exit opening blocking device (16).

17. A method according to claim 16, wherein said exit opening (8) enables a fluid passage from the interior of said brewing device (1) to the exterior of said brewing device (1).

18. A method according to claim 16 or 17, wherein said exit opening (8) enables a fluid passage from an inner compartment (2) inside said brewing device (1) to the exterior of said brewing device (1).

19. A method according to any of the preceding claims, wherein said disposable brewing device (1) is a brewing device (1) according to any of claims 25-39.

20. A method for forming an exit opening (8) in a disposable brewing device (1) so that a brewed liquid inside said brewing device (1) may be poured out of said brewing device (1) through said exit opening (8), said method comprises the steps of

• grabbing a tight hold of at least one free end (21) of an exit opening blocking device (16) being placed between two sheets (22, 23) of sheet material (10) forming at least part of an outer compartment (5) of said brewing device (1), said exit opening blocking device (16) extending in the path of an edge welding (12) of said brewing device (1), and

• pulling said exit opening blocking device (16) at least partly off of said brewing device (1) to break said edge welding (12), thereby forming said exit opening (8).

21. A method according to claim 20, wherein at least a part of said free end (21) of said exit opening blocking device (16) extends beyond the outer perimeter of said outer compartment (5).

22. A method according to claim 21 or 22, wherein said exit opening blocking device (16) is welded to said two sheets (22, 23) of sheet material (10).

23. A method according to any of claims 20-23, wherein said exit opening blocking device (16) is a pull-strip (20).

24. A method according to any of claims 20-23, wherein said method is a method for forming an exit opening (8) in a disposable brewing device (1) produced by a method according to any of claims 1-15.

25. A disposable brewing device (1) comprising aroma material (4), said brewing device (1) comprising a first side sheet (22) and a second side sheet (23) being welded together along an edge of said first side sheet (22) and said second side sheet (23) to form at least part of an outer compartment (5) of said brewing device (1), wherein an exit opening blocking device (16) comprising a pull-strip (20) is arranged between said first side sheet (22) and said second side sheet (23) and wherein said exit opening blocking device (16) extends in the path of said edge welding (12).

26. A disposable brewing device (1) according to claim 25, wherein said exit opening blocking device (16) blocks an exit opening (8) of said outer compartment (5), so that when said exit opening blocking device (16) is removed a brewed liquid may be poured out of said outer compartment (5) through said exit opening (8).

27. A disposable brewing device (1) according to claim 25-26, wherein at least one inner compartment (2) is suspended inside said outer compartment (5).

28. A disposable brewing device (1) according to claim 27, wherein said at least one inner compartment (2) is formed at least partly by a liquid-permeable filter material (31).

29. A disposable brewing device (1) according to claim 27 or 28, wherein said aroma material (4) is located in said at least one inner compartment (2).

30. A disposable brewing device (1) according to any of claims 27-29, wherein said brewing device (1) comprises an entrance opening (3) for introducing liquid into said brewing device (1).

31. A disposable brewing device (1) according to claim 30, wherein said entrance opening (3) extends substantially the entire length (W) of the upper edge (25) of said brewing device (1).

32. A disposable brewing device (1) according to claim 30 or 31, wherein said exit opening (8) is arranged at said entrance opening (3).

33. A disposable brewing device (1) according to any of claims 27-32, wherein said first side sheet (22) and said second side sheet (23) are formed by a flexible film material.

34. A disposable brewing device (1) according to any of claims 27-29, wherein said brewing device (1) is formed as a stand-up pouch, having a contact face (14) adapted for maintaining the longitudinal extent (L) of said brewing device (1) in a substantial vertical stand-up position at least during use for brewing.

35. A disposable brewing device (1) according to any of claims 27-34, wherein said at least one outer compartment (5) being formed at least partly by a film material to be expandable from a non-expanded state when filled with liquid.

36. A disposable brewing device (1) according to any of claims 27-35, wherein said aroma material (4) comprises roast and/or ground coffee, instant coffee, tea, milk powder, herb, fruit, meat, chocolate powder, vegetables, grains or any combination thereof or any other materials which comprises or provides flavour or aroma or other functionalities.

37. A disposable brewing device (1) according to any of claims 27-36, wherein said at least one outer compartment (5) is at least partly formed by a transparent or translucent material.

38. A disposable brewing device (1) according to any of claims 27-37, wherein said exit opening blocking device (16) extends through a part of said edge welding (12).

39. A disposable brewing device (1) according to any of claims 27-38, wherein said disposable brewing device (1) is produced by a method according to any of claims 1- 19.

40. Use of a disposable brewing device (1) according to any of claims 27-39 for brewing of a beverage.