Beverage Capsule With Moldable Filter

Abstract

A beverage capsule is provided having a body defining an opening. A filter is disposed in the opening and secured to the body. The filter is moldable to define an ingredients chamber. The filter is formed of a moldable nonwoven fabric comprising fibers that are undrawn or partially drawn prior to molding. Ingredients are disposed in the ingredients chamber for preparing a desired beverage and a cover is disposed over the opening for sealing the interior space.

I/we claim: 
     
         1 . A beverage capsule for use in a beverage preparing machine, the beverage capsule comprising:
 a body defining an opening;   a filter disposed in said opening and secured to said body, said filter being molded to define an ingredients chamber, said filter being formed of a moldable nonwoven fabric comprising fibers that are undrawn or partially drawn prior to molding;   ingredients disposed in said ingredients chamber for preparing a desired beverage;   a cover disposed over said opening.   
     
     
         2 . A beverage capsule as claimed in  claim 1  wherein said fibers are mechanically bonded. 
     
     
         3 . A beverage capsule as claimed in  claim 3  wherein said fibers are hydroentangled. 
     
     
         4 . A beverage capsule as claimed in  claim 1  wherein said fibers include multi-component fibers. 
     
     
         5 . A beverage capsule as claimed in  claim 4 , wherein said multi-component fibers comprise a first material and a second material wherein said first material has a higher melt temperature than said second material. 
     
     
         6 . A beverage capsule as claimed in  claim 4  wherein said multi-component fibers comprise a first material and a second material wherein said first material has a higher tensile strength than said second material. 
     
     
         7 . A beverage capsule as claimed in  claim 4 , wherein said multi-component fibers are arranged in an islands-in-the-sea configuration. 
     
     
         8 . A beverage capsule as claimed in  claim 7 , wherein said multi-component fibers comprise a first material forming at least one island and a second material forming a sea, wherein said first material has a higher melt temperature than said second material. 
     
     
         9 . A beverage capsule as claimed in  claim 5  wherein said first material comprises polyester. 
     
     
         10 . A beverage capsule as claimed in  claim 9 , wherein said second material comprises PE. 
     
     
         11 . A beverage capsule as claimed in  claim 9 , wherein said first material comprises at least 70% of each multi-component fiber. 
     
     
         12 . A beverage capsule as claimed in  claim 1 , wherein said nonwoven fabric has a basis weight in the range of 40 to 150 gsm. 
     
     
         13 . A beverage capsule as claimed in  claim 1 , wherein said nonwoven fabric has a basis weight in the range of 60 to 120 gsm. 
     
     
         14 . A beverage capsule as claimed in  claim 1 , wherein said body includes a flange that surrounds said opening and wherein said filter includes a gasket portion that is secured to said flange, said gasket portion having a plurality of channels. 
     
     
         15 . A beverage capsule as claimed in  claim 14 , wherein said cover is secured to said gasket portion of said filter over said flange. 
     
     
         16 . A beverage capsule as claimed in  claim 14 , wherein material from said flange and said cover is disposed within said channels of said gasket portion. 
     
     
         17 . A beverage capsule as claimed in  claim 1  wherein said body includes a sidewall and an end wall to define an interior space for containing said ingredients in said ingredients chamber. 
     
     
         18 . A beverage capsule for use in a beverage preparing machine, the beverage capsule comprising:
 a body defining an opening;   a filter disposed in said opening and secured to said body, said filter being molded to define an ingredients chamber, said filter being formed of a moldable nonwoven fabric comprising multi-component fibers that are undrawn or partially drawn prior to molding, wherein said multi-component fibers are formed of materials including polyester;   ingredients disposed in said ingredients chamber for preparing a desired beverage; and   a cover disposed over said opening.   
     
     
         19 . A beverage capsule as claimed in  claim 18 , wherein said multi-component fibers comprise a first material forming at least one island and a second material forming a sea, wherein said first material comprises polyester. 
     
     
         20 . A beverage capsule as claimed in  claim 19  wherein said second material comprises PE.