Highly recyclable beverage pods and method of manufacture

Abstract

A method of manufacture for highly recyclable beverage pods, wherein the method includes providing a beverage pod having a cavity and an interior surface within the cavity, 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, having a headspace atmosphere, modifying the headspace atmosphere within the cavity, sealing the cavity with an airtight lid, and discharging the beverage pod into a secondary packaging operation, producing a highly recyclable beverage pod containing a cavity with a shell, a filter disc disposed within the cavity, a formed filter material adhered to an interior surface of the cavity, a beverage material within the formed filter material, and an airtight lid configured to seal the filter disc, the formed filter material, and the beverage material.

What is claimed is: 
     
         1 . A beverage pod comprising:
 a cavity comprised of a beverage pod shell, wherein the beverage pod shell comprises one or more detents configured to interlock with one or more beverage pods;   a filter disc disposed within the cavity;   a formed filter material adhered to an interior surface of the cavity;   a beverage material within the formed filter material; and   an airtight lid sealing the filter disc, the formed filter material, and the beverage material within the cavity.   
     
     
         2 . The beverage pod of  claim 1 , wherein the one or more detents are round. 
     
     
         3 . The beverage pod of  claim 1 , wherein the one or more detents are square. 
     
     
         4 . The beverage pod of  claim 1 , wherein the beverage pod shell comprises an exterior surface and an interior surface configured to interlock with one or more other beverage pods when stacked and the beverage pod shell is comprised of aluminum material. 
     
     
         5 . The beverage pod of  claim 4 , wherein the exterior surface of the beverage pod shell comprises a first twist groove configured to interlock with a complimentary interior surface of a second beverage pod, wherein the complimentary interior surface comprises a second twist groove. 
     
     
         6 . The beverage pod of  claim 4 , wherein the exterior surface of the beverage pod shell comprises the one or more detents, wherein the one or more detents are configured to interlock with a complimentary interior surface of a second beverage pod shell, wherein the complimentary interior surface comprises one or more recesses. 
     
     
         7 . The beverage pod of  claim 6 , wherein the one or more detents and the one or more recesses are configured in a straight alignment. 
     
     
         8 . The beverage pod of  claim 6 , wherein the one or more detents and the one or more recesses are configured in a staggered alignment. 
     
     
         9 . The beverage pod of  claim 6 , wherein the one or more detents and the one or more recesses are configured in a threaded channel alignment. 
     
     
         10 . The beverage pod of  claim 4 , wherein the interior surface of the beverage pod shell comprises on or more detents, wherein the one or more detents are configured to interlock with a complimentary exterior surface of a second beverage pod shell, wherein the complimentary exterior surface comprises one or more recesses. 
     
     
         11 . The beverage pod of  claim 10 , wherein the one or more detents and the one or more recesses are configured in a straight alignment. 
     
     
         12 . The beverage pod of  claim 10 , wherein the one or more detents and the one or more recesses are configured in a staggered alignment. 
     
     
         13 . The beverage pod of  claim 10 , wherein the one or more detents and the one or more recesses are configured in a threaded channel alignment. 
     
     
         14 . The beverage pod of  claim 4 , wherein the exterior surface comprises a first set of circumferential beads configured to interlock with a complimentary interior surface of a second beverage pod, wherein, wherein the complimentary interior surface comprises a second set of circumferential beads. 
     
     
         15 . The beverage pod of  claim 14 , wherein the first set of circumferential beads and the second set of circumferential beads are configured in a diagonal alignment. 
     
     
         16 . The beverage pod of  claim 14 , wherein the first set of circumferential beads and the second set of circumferential beads are configured in a straight alignment. 
     
     
         17 . The beverage pod of  claim 1 , wherein the one or more detents are stamped into the beverage pod shell on one or more surfaces. 
     
     
         18 . The beverage pod of  claim 1 , wherein the one or more detents are accomplished by adding material to a surface of the beverage pod shell. 
     
     
         19 . The beverage pod of  claim 1 , wherein the airtight lid is sealed with a frangible seal, enabling a user to peel the airtight lid from the beverage pod shell. 
     
     
         20 . A method of manufacture for beverage pods, wherein the method comprises:
 providing a beverage pod having a cavity and an interior surface within the cavity;   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 with beverage material, having a headspace atmosphere;   modifying the headspace atmosphere within the cavity; and   sealing the cavity with an airtight lid.