U.S. patent application number 12/077082 was filed with the patent office on 2009-09-17 for packaging system to provide fresh packed coffee.
Invention is credited to Gerard Laurent Buisson, Thomas James Manske, JR., Douglas Bruce Zeik.
Application Number | 20090232947 12/077082 |
Document ID | / |
Family ID | 41063312 |
Filed Date | 2009-09-17 |
United States Patent
Application |
20090232947 |
Kind Code |
A1 |
Buisson; Gerard Laurent ; et
al. |
September 17, 2009 |
Packaging system to provide fresh packed coffee
Abstract
A packaging system useful for roast and ground coffee, having a
container with a bottom, a top, and a body enclosing a perimeter
between the bottom and the top. A flexible closure is removably
attached and sealed to the protuberance so that the closure seals
the interior volume of the container.
Inventors: |
Buisson; Gerard Laurent;
(Cincinnati, OH) ; Manske, JR.; Thomas James;
(Mason, OH) ; Zeik; Douglas Bruce; (Middletown,
OH) |
Correspondence
Address: |
Calfee, Halter & Griswold LLP
800 Superior Ave., Sts. 1400
Cleveland
OH
44114
US
|
Family ID: |
41063312 |
Appl. No.: |
12/077082 |
Filed: |
March 14, 2008 |
Current U.S.
Class: |
426/118 ;
220/203.29; 220/62.21; 383/103 |
Current CPC
Class: |
B65D 51/1644 20130101;
B65D 81/20 20130101; B65D 79/005 20130101 |
Class at
Publication: |
426/118 ;
220/203.29; 220/62.21; 383/103 |
International
Class: |
B65D 81/20 20060101
B65D081/20; B65D 51/16 20060101 B65D051/16; B65D 33/01 20060101
B65D033/01 |
Claims
1. A packaging system comprising: a container for holding an
off-gassing substance and having a longitudinal axis and comprising
a bottom, a top, and a body having an enclosed perimeter between
the bottom and the top, wherein the bottom, top, and body together
define an interior volume; and the body comprises a multi-layered
structure including a collapsible inner layer which holds the
off-gassing substance and collapses and expands within the interior
volume to compensate for changes in pressure resulting from
off-gassing of the substance.
2. The packaging system of claim 1, wherein the collapsible inner
layer comprises a bag.
3. The packaging system of claim 2, wherein the top of the bag
comprises an upper edge and the container comprises an upper edge,
and the upper edge of the bag is sealed to the upper edge of the
container.
4. The packaging system of claim 3, wherein a one-way valve is
disposed in the bag.
5. The packaging system of claim 1, wherein at least one layer of
the body comprises an oxygen barrier.
6. The packaging system of claim 1, wherein the layers of the body
other than the collapsible inner layer comprise at least one region
of deflection, wherein the region of deflection allows flexion and
thereby has less resistance to flexing than an area proximate to
the region of deflection.
7. The packaging system of claim 1, wherein at least one of the
layers of the body is blow-molded, and comprises a material
selected from the group consisting of polycarbonate, linear low
density polyethylene, low density polyethylene, high density
polyethylene, polyethylene terephthalate, polypropylene,
polystyrene, polyvinyl chloride, co-polymers thereof, and
combinations thereof.
8. The packaging system of claim 1, further comprising a flexible
closure removably attached and sealed to the top of the container,
and an overcap.
9. The packaging system of claim 8, wherein the flexible closure
has a one-way valve disposed therein.
10. The packaging system of claim 8, wherein the body includes a
protuberance proximate to the top, and the closure is removably
attached to the protuberance.
11. The packaging system of claim 1, wherein the substance is roast
and ground coffee.
12. The packaging system of claim 1, wherein a one-way valve is
disposed in the collapsible inner layer.
13. The packaging system of claim 1, wherein the collapsible inner
layer comprises an outer surface, and all or part of the outer
surface is non-permanently attached to an adjacent layer of the
body.
14. The packaging system of claim 13, wherein all or part of the
outer surface is laminated to the adjacent layer.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a packaging system useful
for packing fresh roast and ground coffee. The present invention
still further relates to a more convenient, lightweight container
that provides increased strength per mass unit of plastic for the
transport of freshly roast and ground coffee.
BACKGROUND OF THE INVENTION
[0002] Packages such as cylindrical cans for containing a
particulate product under pressure, such as roast and ground
coffee, are representative of various articles to which the present
invention is applicable. It is well known in the art that freshly
roasted and ground coffee evolutes substantial amounts of oils and
gases, such as carbon dioxide, particularly after the roasting and
grinding process. Therefore, roast and ground coffee is usually
held in storage bins prior to final packing to allow for maximum
off gassing of these volatile, natural products. The final coffee
product is then placed into a package and subjected to a vacuum
packing operation.
[0003] Vacuum packing the final coffee product results in reduced
levels of oxygen in the headspace of the package. This is
beneficial, as oxygen reactions are a major factor in the staling
of coffee. A common package used in the industry is a cylindrical,
tin-plated, and steel stock can. The coffee is first roasted, and
then ground, and then vacuum packed within a can, which must be
opened with a can opener, common to most households.
[0004] Packing coffee immediately after roasting and grinding
provides substantial process savings, as the coffee does not
require storage to complete the off-gas process. Also, the off-gas
product usually contains high quantities of desirable volatile and
semi-volatile aromatic compounds that easily volatilize and prevent
the consumer from receiving the full benefit of the coffee drinking
process. Furthermore, the loss of these aromatic compounds makes
them unavailable for release in a standard container; thereby
preventing the consumer from the full reception of the pleasurable
burst of aroma of fresh roast and ground coffee. This aroma burst
of volatile compounds is much more perceptible in a pressurized
package than in a vacuum packed package.
[0005] It is therefore an object of the present invention to
provide a handled package for roast and ground coffee that provides
a lighter weight, fresher packing, easier-opening, peelable seal,
and "burpable" closure alternative to a standard heavy can.
SUMMARY OF THE INVENTION
[0006] The present invention relates to a fresh packaging system
for roast and ground coffee.
[0007] The present invention also relates to a method for packing
coffee using the fresh packaging system for roast and ground
coffee.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is an exploded perspective view of a preferred
embodiment of the fresh packing system in accordance with the
present invention;
[0009] FIG. 2 is an exploded perspective view of an alternative
embodiment of the fresh packing system;
[0010] FIG. 3 is a cross-sectional view of an exemplary closure and
one-way valve assembly for the fresh packing system;
[0011] FIG. 4 is a cross-sectional view of an exemplary overcap
assembly for a fresh packing system;
[0012] FIG. 5 is an expanded, cross-sectional view of the region
labeled 5 in FIG. 4 of the overcap in an applied position;
[0013] FIG. 6 is an expanded, cross-sectional view of the region
labeled 5 in FIG. 4 of the overcap in an expanded position;
[0014] FIG. 7 is an elevational view of an alternative embodiment
of the fresh packing system;
[0015] FIG. 7A is a bottom planar view of the embodiment of FIG.
7;
[0016] FIG. 8 is a perspective view of an alternative embodiment of
the fresh packing system;
[0017] FIG. 8A is a perspective view of an alternative embodiment
of the fresh packing system;
[0018] FIG. 9 is an isometric view of an alternative exemplary
overcap for use with a fresh packing system;
[0019] FIG. 9A is a bottom planar view of the alternative exemplary
overcap of FIG. 9;
[0020] FIG. 10 is a cross-sectional view of the region labeled 10
in FIG. 9 in contact with a fresh packaging system;
[0021] FIG. 11 is a perspective view of an alternative embodiment
of the fresh packaging system;
[0022] FIG. 12 is a cross-sectional view of FIG. 11;
[0023] FIG. 13 is a cross-sectional view of another exemplary
overcap assembly for a fresh packing system;
[0024] FIG. 14 is a perspective view of another exemplary overcap
assembly for a fresh packing system;
[0025] FIG. 15 is a perspective view of another exemplary overcap
assembly for a fresh packing system;
[0026] FIG. 16 is a perspective view of an alternative embodiment
of the fresh packaging system;
[0027] FIG. 17A is a side view of an alternative embodiment of the
fresh packaging system, in a collapsed condition;
[0028] FIG. 17B is a perspective view of the fresh packaging system
of FIG. 17A, in an expanded condition; and
[0029] FIG. 18 is a perspective view of an alternative embodiment
of the fresh packaging system.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present invention is related to a fresh packaging system
for roast and ground coffee. The packaging system comprises a
container comprising a bottom, a top and a body having an enclosed
perimeter between the bottom and the top where the top, bottom, and
body together define an interior volume. A flexible closure is
removably attached and sealed to the body proximate to the top. The
container bottom and body are constructed from a material having a
tensile modulus number ranging from at least about 35,000 pounds
per square inch (2,381 atm) to at least about 650,000 pounds per
square inch (44,230 atm), which provides a top load capacity of at
least about 16 pounds (7.3 Kg).
[0031] The invention is more generally related to a method for the
packing of coffee using the container of the present invention. The
method steps include filling the container system described above
with roast and ground coffee, flushing the container with an inert
gas, and, sealing the container with a flexible closure.
[0032] The invention is also related to an article of manufacture
that provides the end user with beneficial coffee aroma
characteristics. Roast and ground coffee is contained within the
interior volume such that the article of manufacture has an overall
coffee aroma value of at least about 5.5. (A method for measuring
the overall coffee aroma value is described in the Test Methods
section, infra.)
[0033] At least one purpose of the present invention, inventive
method, and article of manufacture is to provide a useful benefit
to the user that includes, but is not limited to, providing a roast
and ground coffee with a perceived more fresh and aromatic flavor.
Such a container system also provides an easy to use and low cost
means of delivery of a roast and ground coffee to an end user.
[0034] Preferably, but optionally, the container has a handle
element disposed thereon. More preferably the handle element is
integral with the body of the container. This handle element
facilitates gripping of the container system by the end user. This
gripping is particularly useful for users with small hands or hands
in a weakened condition due to illness, disease, or other medical
malady.
[0035] Optionally, but preferably, at least one embodiment of the
present invention features a one-way valve to release excess
pressure built up within the container due to the natural off gas
process of roast and ground coffee. It is also believed that
changes in external temperature and altitude can also cause the
development of pressure internal to the container. The one-way
valve is selected to release coffee off gas in excess of a
predetermined amount however, remains sealed after such a release,
thereby retaining an aromatically pleasing amount of off gassed
product within the container.
[0036] Another optional, but preferred, feature is an overcap
placed over the closure. The overcap can comprise a dome, or
cavity, that allows positive, outward deformation of the closure
due to the pressure build-up within the container. The overcap is
preferably air tight and flexible to allow for easy application in
manufacture, either with, or without, a closure, and by the end
user, after end user removal, of a closure. A flexible overcap can
also allow the end user to remove excess air by compressing the
dome, thereby releasing excess ambient air from the previously open
container (burping). However, the overcap can also exhibit less
flexibility or be inflexible. The overcap also provides for a tight
seal against the rim of the container after opening by the end
user. This tight seal prevents pollution of the rim, resulting in
an undesirable expectoration of the overcap after application. The
overcap can also optionally allow for stacking several container
embodiments when the closure and the dome portion of the overcap
are at a point of maximum deflection. The overcap also optionally
has a vent to allow for easy removal of vented off gas product
trapped between the closure and overcap assemblies, but still
allows for "burping."
[0037] In a preferred embodiment, the overcap can have a rib
disposed proximate to and along the perimeter of the overcap
defining an inner dome portion and an outer skirt portion. The rib
forms a hinge-like structure so that outward deflection of the
inner dome portion caused by deflection of the closure due to
coffee off gassing causes the rib to act as a cantilever for the
skirt portion. Thus, outward deflection of the dome portion causes
the skirt portion to deflect inwardly on an outer portion of the
container wall, resulting in an improved seal characteristic and
improves retaining forces of the overcap with respect to the
container.
The Container
[0038] Referring to FIG. 1, fresh packaging system 10, generally
comprises a container 11 made from a compound, for example, a
polyolefin. Exemplary and non-limiting compounds and polyolefins
that can be used for producing the present invention include
polycarbonate, linear low-density polyethylene, low-density
polyethylene, high-density polyethylene, polyethylene
terephthalate, polypropylene, polystyrene, polyvinyl chloride,
co-polymers thereof, and combinations thereof. It should be
realized by one skilled in the art that container 11 of the present
invention can take any number of shapes and be made of any number
of suitable materials. Container 11 generally comprises an open top
12, a closed bottom 13, and a body portion 14. Open top 12, closed
bottom 13, and body portion 14 define an inner volume in which a
product is contained. Also, closed bottom 13 and body portion 14
are formed from a material having a tensile modulus ranging from at
least about 35,000 pounds per square inch (2,381 atm) to at least
about 650,000 pounds per square inch (44,230 atm), more preferably
from at least about 40,000 pounds per square inch (2,721 atm) to at
least about 260,000 pounds per square inch (17,692 atm), and most
preferably ranging from at least about 95,000 pounds per square
inch (6,464 atm) to at least about 150,000 pounds per square inch
(10,207 atm). Tensile modulus is defined as the ratio of stress to
strain during the period of elastic deformation (i.e., up to the
yield point). It is a measure of the force required to deform the
material by a given amount and is thus, a measure of the intrinsic
stiffness of the material.
[0039] It is preferred that bottom portion 13 be disposed concave
inwardly, or recessed, towards the inner volume so that undesirable
deflections caused by pressure increases within the inner volume
are minimized. If the bottom 13 expands outwardly sufficiently,
causing the bottom 13 to concave outwardly, then the container 11
will develop what is generally referred to in the art as "rocker
bottom." That is, if the bottom 13 deflects outwardly so that the
container system 10 will not be stable while resting on a flat
surface, fresh packaging system 10 will tend to rock back and
forth.
[0040] As shown in FIG. 7A, a plurality of protrusions 40 can be
disposed on the closed bottom 13 of container 11 about the
longitudinal axis of container 11. In a preferred embodiment,
protrusions 40 form an oblique angle with the closed bottom 13 of
container 11. If the container 11 assumes a cylindrical shape, it
is believed that protrusions 40 can be rectilinearly disposed about
the diameter of the closed bottom 13 of container 11. However, one
of skill in the art would realize that protrusions 40 could be
disposed on the closed bottom 13 of container 11 in any geometrical
arrangement. Without wishing to be bound by theory, it is believed
that protrusions 40 can protrude past the geometry of the closed
bottom 13 of container 11 upon an outward deflection of the closed
bottom 13 of container 11. In this way container 11 can maintain a
stable relationship with other surfaces should "rocker bottom" be
realized upon the development of an outward pressure from within
container 11. While the preferred embodiment utilizes four
protrusions 40 disposed on closed bottom 13, it should be realized
by one of skill in the art that virtually any number of protrusions
40 could be disposed on closed bottom 13 to yield a stable
structure upon outward deflection of closed bottom 13.
Additionally, protrusions 40 could be a square, triangular,
elliptical, quad-lobe, pentaloid, trapezoidal, arranged in multiply
nested configurations, provided in an annular ring about closed
bottom 13, and combinations thereof.
[0041] Again referring to FIG. 7A, an annular ring 42, or any other
raised geometry, including interrupted geometrical configurations,
can be disposed on closed bottom 13 of container 11. Annular ring
42 could be dimensioned to facilitate nesting, or stacking, of
multiple embodiments of containers 11. In other words, annular ring
42 could be designed to provide serial stacking of a container 11
onto the overcap 30 of the preceding, or lower, container 11.
Without wishing to be bound by theory, it is believed that the
facilitation of nesting by the use of annular ring 42 disposed on
closed bottom 13 of container 11 provides enhanced structural
stability.
[0042] It is also believed that the closed bottom 13 of container
11 could be designed, in what is known to those of skill in the
art, as a quad lobe, or pentaloid. Again, without desiring to be
bound by theory, it is believed that such a quad lobe, or
pentaloid, design could provide enhanced ability to resist the
deformation of closed bottom 13 of container 11 due to internal
pressures developed within container 11.
[0043] Referring again to FIG. 1, container 11 can be cylindrically
shaped with substantially smooth sides. Handle portions 15 are
respectively formed in container body portion 14 at arcuate
positions. A plurality of anti-slip strips 16 can be formed at a
predetermined interval within handle portions 15. Handle portions
15 are formed as would be known to one skilled in the art to
provide a gripping surface at a most efficacious position to enable
users with small hands or debilitating injuries or maladies to grip
container portion 11 with a minimum of effort. Further, container
11 can be readily grasped by hand due to the configuration
described above.
[0044] Additionally, container 11 can optionally have a
protuberance 17 in the form of a rim like structure disposed at the
open end of container 11. Protuberance 17 can provide a surface
with which to removably attach closure 18 and provide a locking
surface for skirt portion 32 of overcap 30. The protuberance 17 may
be continuous as shown in FIG. 1, or it may be discontinuous. A
discontinuous protuberance may be formed by a series of tabs or
ridges protruding inwardly or outwardly around the open top 12 of
the container 11. Also, a continuous protuberance could extend only
part-way around the periphery of the open top 12. In such
embodiments, the closure 18 could be partly sealed to the
protuberance and partly sealed to the top rim of the container 11,
or sized to have a close, press fit with the container 11.
Similarly, in the complete absence of any protuberance 17, the
closure 18 may simply be sealed to the top rim of the container or
be sized such that it has a close, press fit with container 11.
[0045] In an alternative embodiment as shown in FIG. 2, container
11a can be parallelepiped shaped with substantially smooth sides.
Handle portions 15a are respectively formed in container body
portion 14a at arcuate positions. A plurality of gripping
projections 16a are formed at a predetermined interval within
handle portions 15a. Corresponding closure 18a and overcap 30a are
fitted on container 11a as would be known to one skilled in the
art.
[0046] In an alternative embodiment, as shown in FIG. 7, handle
portions 15b can preferably be symmetrical. Without desiring to be
bound by theory, it is believed that symmetrical handle portions
15b could prevent inversion of the handle portions 15b upon an
increase in pressure from within container 11b. It is believed that
symmetrically incorporated handle portions 15b provides for the
uniform distribution of the internal pressure, developed within
container 11, throughout handle portion 15b.
[0047] As is also shown in the alternative embodiment of FIG. 7,
all portions of handle portions 15b are presented as either
parallel to the longitudinal axis of container 11b or perpendicular
to the longitudinal axis of container 11b. Without desiring to be
bound by theory, it is believed that handle portions 15b, arranged
to provide all component portions of handle portions 15b to be
either parallel or perpendicular to the longitudinal axis of
container 11b, could be less susceptible to bending forces due to
internal pressures developed within container 11b. This could aid
in the prevention of catastrophic failure of the container due to
the pressures generated internally to container 11b.
[0048] Further, providing container 11b with handle portions 15b in
a recessed configuration with respect to the body portion 14b of
container 11b could require less force from the end user to
maintain a firm grip on handle portions 15b of container 11b.
Additionally, recessed handle portions 15b could aid in the
prevention of an end user supplying extraneous force to the
external portions of container 11b thereby causing catastrophic
failure or deformation of container 11b.
[0049] Of course, a handle portion is merely optional. As potential
alternatives, a sticky or slip resistant gripping surface (in
addition to or in lieu of a handle) would be known to one of
ordinary skill. A slip resistant surface having a relatively high
coefficient of friction with respect to a person's hand, for
example, or otherwise having a texture that aids gripping can be
utilized. A high coefficient of friction could be achieved by use
of a light tack adhesive, or a rubber-like material being disposed
at portions of the container 11. A gripping texture could be
achieved by incorporating a relatively rough surface, such as that
of sand paper, on the outside surface of container 11. In another
embodiment, a container could be shaped to conform to a user's
hand. A container having a narrow, oval-shaped cross section, for
example, could be gripped by a user's hand. Further, a container of
virtually any shape beyond those above and those in the Figures can
be configured such that it is grippable without the use of a
conventional handle. In addition, one could simply make a container
without any sort of handle or gripping surface, such as shown in
FIGS. 8 and 8A.
[0050] In one embodiment, the handle portion could be a part of the
overcap, such as the overcap described below. In such an
embodiment, an overcap can have attached or integrally molded
thereto a handle such as a strap, loop, band, or other material
that permits a person to grasp or grip the overcap for carrying.
Further, the handle portion can be of a rigid material, such as the
same material as the body, and could then extend outwardly and away
from the overcap to provide a handle for a consumer to simply grab.
In one embodiment, the bottom of the container 11 can have a shape
having a depression of a suitable size to enable one container to
be stacked upon another, wherein the handle portion of the overcap
of the lower container can fit within the depression of the bottom
of the upper container.
[0051] Referring again to FIG. 1, container 11 exhibits superior
top load strength per mass unit of plastic. With the present
invention, filled and capped containers can be safely stacked one
upon another without concern that the bottom containers will
collapse or be deformed. Often, containers are palletized, by which
several containers are stacked in arrays that take on a cubic
configuration. On the order of 60 cases, each weighing about 30
pounds (13.6 Kg), can be loaded onto a pallet. In certain
instances, these pallets can be stacked one upon another. It will
be appreciated that the bottommost containers will be subjected to
extraordinary columnar forces. Traditionally, polymeric containers
are not capable of withstanding such high column forces. Thus, to
avoid collapsing or buckling of these stacking situations, the top
load resistance of each container should be at least about 16
pounds (7.3 Kg) when the containers are in an ambient temperature
and pressure environment. More preferably, each container should
exhibit a top load resistance of at least about 48 pounds (21.8 Kg)
in accordance with the present invention.
[0052] In at least one embodiment of the present invention, top
load resistance is the amount of force an empty container can
support prior to the occurrence of a deflection parallel to the
longitudinal axis of the container of greater than 0.015 inches. By
way of a non-limiting example, a cylindrical container comprising a
laminate structure (as detailed infra), having an average overall
mass of 39 grams, an average internal volume of approximately 950
cubic centimeters, an average wall thickness of approximately 0.030
inches, and an average diameter of approximately 100 millimeters is
considered not to have a top load resistance greater than 16 pounds
(7.3 Kg) when the container deflects more than 0.015 inches in a
direction parallel to the longitudinal axis when a 16 pound load is
placed thereupon. As is known to one of skill in the art, top load
resistance can be measured using a suitable device such as an
Instron, model 550R1122, manufactured by Instron, Inc., Canton,
Mass. The Instron is operated in a compressive configuration with a
1000 pound load cell and a crosshead speed of 1.0 inch/minute. The
load is applied to the container through a platen that is larger
than the diameter of the subject container.
[0053] As shown in FIG. 7, the body portion 14b of container 11b
can have at least one region of deflection 43 placed therein to
isolate deflection of the container 11b due to either pressures
internal to container 11b or pressures due to forces exerted upon
container 11b. As shown, at least one region of deflection 43 could
generally define rectilinear regions of container 11b defined by a
cylindrical wall. However, one of skill in the art would realize
that at least one region of deflection 43 incorporated into body
portion 14b could assume any geometry, such as any polygon, round,
or non-uniform shape. Without wishing to be bound by theory, it is
believed that a purely cylindrical container 11b, having a uniform
wall thickness throughout, will resist compression due to pressure
exerted from within container 11b or external to container 11b.
However, without desiring to be bound by theory, it is believed
that when applied forces exceed the strength of the container wall
of purely cylindrical container 11b, deflection could be exhibited
in an undesirable denting or buckling. Any non-uniformities present
in a purely cylindrical container 11b, such as variations in wall
thickness, or in the form of features present, such as handle
portions 15b, can cause catastrophic failure upon a differential
pressure existing between regions external to container 11b and
regions internal to container 11b.
[0054] However, the incorporation of at least one region of
deflection 43 is believed to allow flexion within the body portion
14b of container 11b. Thus, it is believed that body portion 14b
can deform uniformly without catastrophic failure and can resist
undesirable physical and/or visual effects, such as denting. In
other words, the volume change incurred by container 11b due to
internal, or external, pressures works to change the ultimate
volume of the container 11b to reduce the differential pressure and
thus, forces acting on the container wall. It is also believed,
without desiring to be bound by theory, that the incorporation of a
solid or liquid, or any other substantially incompressible
material, can provide substantial resistance to the inward
deflection of at least one region of deflection 43. For example,
the inclusion of a powder, such as roast and ground coffee, could
provide resistance to the inward deflection of at least one region
of deflection 43, thus enabling at least one region of deflection
43 to remain substantially parallel to the longitudinal axis of
container 11b and thereby providing an effective increase in the
top load capability of container 11b. The peelable laminate seal
also deflects with external pressure changes further reducing the
pressure load on the container.
[0055] Thus, the amount of material to be stored within the
container 11b (or any other container disclosed herein) may be
measured to avoid an excessive amount of "outage." An "outage" is a
free space between the top of the stored material in the container,
and the underside of the closure above the coffee. Depending on the
material's density or resistance to compression, the material's
natural tendency to resist inward deflection of the portion of the
container 11b wall surrounding the material can aid in reducing or
eliminating unwanted container wall deformation. Because the
portion of the container 11b wall surrounding any outage above the
material is more likely to deflect inwardly upon a decrease of
pressure within the container, by filling the container to
eliminate or minimize this outage, there are less unsupported
portions of the container having less resistance to deflection.
Thus, reducing the amount of outage by packing the container 11b
substantially full of material reduces the tendency of unsupported
portions of the container to deflect, so that the container 11b
uniformly responds to differences in pressure.
[0056] Along the same lines, increasing the density of the stored
material increases the structural support provided by the stored
material. Granular material such as roast ground coffee, if packed
tightly enough, can add support to the container and may reduce the
amount of container material, e.g. blow-molded plastic, needed for
the container to support itself and resist external pressure,
including pressure due to top loads. In addition, sufficiently
reducing the outage may even eliminate the need for any regions of
deflection, as the structural integrity of the container in
combination with the support provided by the stored material can in
come cases be sufficient to resist any deformations resulting from
pressure differentials within a sufficient range.
[0057] In a non-limiting, but preferred embodiment, container 11b
has at least one region of deflection 43 that can be presented in
the form of rectangular panels. The panels have a radius that is
greater than the radius of container 11b. The panels are designed
to have less resistance to deflection than that of the region of
container 11b proximate to the rectangular panels. Thus, any
movement exhibited by the panels is isolated to the panels and not
to any other portion of container 11b.
[0058] As shown in FIG. 1, without desiring to be bound by theory,
it is believed that the chime should be sufficient to allow
container 11 to compress under vacuum by adapting to base volume
changes and will improve the top loading capability of container
11. However, it is further believed that the chime should be as
small as is practicable as would be known to one of skill in the
art.
[0059] As shown in FIG. 7, the body portion 14b of container 11b
can also have at least one rib 45 incorporated therein. It is
believed that at least one rib 45 can assist in the effective
management of isolating the movement of at least one panel 43 by
positioning at least one rib 45 parallel to the longitudinal axis
of container 11b and proximate to at least one panel 43 in order to
facilitate the rotational movement of at least one panel 43 upon an
inward, or outward, deflection of at least one panel 43. Further,
it is believed that at least one rib 45 can also provide added
structural stability to container 11b in at least the addition of
top load strength. In other words, at least one rib 45 could
increase the ability of container 11b to withstand added pressure
caused by the placement of additional containers or other objects
on top of container 11b. One of skill in the art would be able to
determine the positioning, height, width, depth, and geometry of at
least one rib 45 necessary in order to properly effectuate such
added structural stability for container 11b. Further, it would be
known to one of skill in the art that at least one rib 45 could be
placed on container 11b to be parallel to the longitudinal axis of
container 11b, annular about the horizontal axis of container 11b,
or be of an interrupted design, either linear or annular to provide
the appearance of multiple panels throughout the surface of
container 11b.
[0060] Additionally, container 11b can generally have a finish 46
incorporated thereon. In a preferred embodiment, the finish 46 is
of an annular design that is believed can provide additional hoop
strength to container 11b and surprisingly, can provide a finger
well to assist the user in removal of overcap 30. Further, it is
possible for one of skill in the art to add ribs 47 to finish 46 in
order to provide further strength to container 11b in the form of
the added ability to withstand further top loading. In a preferred
embodiment, ribs 47 are disposed parallel to the horizontal axis of
container 11b and perpendicular to finish 46.
[0061] Referring to FIGS. 11 and 12, it was found that a container
11e provided with a protuberance 17a that is at least substantially
outwardly facing from body portion 14 and substantially
perpendicular to the longitudinal axis of container 11e can have
less induced structural stress caused by a vacuum internal to
container 11e in the junction 80 proximate to the interface of
protuberance 17a and body portion 14. Without desiring to be bound
by theory, it is believed that such forces exerted on an outwardly
facing protuberance 17a would cause an increase in the radius of
curvature of protuberance 17 with respect to body portion 14,
thereby reducing the overall vacuum induced stresses on the
container lie. Reducing vacuum-induced stresses can facilitate
producing container 11e with a smaller overall wall thickness.
[0062] In addition, it can be desirable for container 11e to be
provided with at least a substantially outwardly facing
protuberance 17a so that static vertical loads (TL) are transferred
through the body portion 14 rather than through protuberance 17a.
Without desiring to be bound by theory, it is believed that
transferring the forces exerted by a load (TL) positioned on top of
container 11e through body portion 14 rather than upon protuberance
17a can reduce overall stresses at junction 80 of protuberance 17a
with body portion 14. This reduction in stresses at junction 80 can
facilitate producing container 11e with a smaller overall wall
thickness.
[0063] Further, container 11e can be combined with an overcap (not
shown in FIGS. 11 and 12) that can substantially direct the forces
exerted by a load to body portion 14 rather than to protuberance
17a. It is believed that any stress at junction 80 caused by a load
positioned on top of container 11e having such an overcap disposed
thereon can be reduced because the deflection of the cantilevered
protuberance 17a is restrained. This can result in lower
concentrations of stress at junction 80.
[0064] There are of course alternative methods of making a
container having sufficient structural integrity to resist
catastrophic collapse due to external pressure (such as pressure
due to loading other containers on top of the container) or
catastrophic explosion due to internal pressure (such as pressure
caused by the de-gassing process of the roasted and ground coffee
within the container). One such method is to manufacture the
container structure with walls having sufficient thickness so that
the rigidity of the structure is sufficient to withstand such
pressures. This alternative, however, increases the amount of
material required to make the container and hence increases its
cost, relative to using a region of deflection as described above.
In one such embodiment, the container could be completely round. No
regions of deflection would be needed in such an embodiment because
the rigidity of the structure could be sufficient to withstand the
pressures.
[0065] In addition, returning again to FIG. 1, the flexible and
peelable closure 18 or a portion thereof may expand outwardly and
contract inwardly, compensating for changes in internal pressure
within the container. In one such embodiment, the expansion and
contraction of the flexible closure 18 could compensate for
relatively small changes in pressure, while a one-way valve 20
opens to compensate for larger pressure changes. In another such
embodiment, there is no one-way valve, and the expansion and
contraction of the flexible closure 18 alone is sufficient to
compensate for the pressure changes within the container 11. Such
flexure of the closure 18 may be either substantially elastic,
whereby the closure 18 or a portion thereof returns substantially
to its original configuration upon pressure equalization, or
substantially non-elastic, whereby the closure 18 remains in its
deformed expanded or collapsed condition upon pressure
equalization. This embodiment may also be used in conjunction with
a one-way valve, as described in connection with other embodiments.
It may also be used with an additional region of deflection in the
container, as described in connection with other embodiments.
[0066] Similarly, in the absence of the flexible closure 18, an
overcap or a portion thereof could include a region of deflection.
Such an embodiment is shown in FIG. 14 wherein the overcap 110 with
a region of deflection 112 may be sealed to a container 114 with a
tamper-band 116, which may include a hermetic seal. An overcap 110
with tamper-band 116 may be used with or without a protuberance at
the top of the container 114. This embodiment may also be used in
conjunction with a one-way valve 118, as described in connection
with other embodiments. It may also be used with an additional
region of deflection 120 in the container 114, as described in
connection with other embodiments.
[0067] One of ordinary skill will know of several alternative ways
to hermetically seal an overcap to a container without a flexible
closure 18. One such example is a mating screw arrangement between
the overcap and the container. The screw arrangement, as is common
on any food container with a screw-on/off top, can have threads
that permit complete sealing in a fraction of a turn of the
overcap, such as a 1/4-turn seal. Of course, a screw on top may
turn more or less than 1/4-turn in order to completely mate or
unmate the top. As another representative example, shown in FIG.
15, an overcap 130 may include a plug arrangement 132 and 134 which
provides a hermetic seal in a known manner. Such overcaps may be
used with or without a protuberance at the top of the container,
and may also be used in conjunction with a one-way valve. They may
also be used with an additional region of deflection in the
container.
[0068] The container 11 is preferably produced by blow molding a
polyolefinic compound. Polyethylene and polypropylene, for example,
are relatively low cost resins suitable for food contact and
provide an excellent water vapor barrier. However, it is known in
the art that these materials are not well suited for packaging
oxygen-sensitive foods requiring a long shelf life. As a
non-limiting example, ethylene vinyl alcohol (EVOH) can provide
such an excellent barrier. Thus, a thin layer of EVOH sandwiched
between two or more polyolefinic layers can solve this problem.
Therefore, the blow-molding process can be used with multi-layered
structures by incorporating additional extruders for each resin
used. Additionally, the container of the present invention can be
manufactured using other exemplary methods including injection
molding and stretch blow molding.
[0069] In a preferred embodiment in accordance with the present
invention, container 11 of FIG. 1, container 11a of FIG. 2, and
container 11b of FIG. 7, or any other container, can be blow molded
from a multi-layered structure to protect an oxygen barrier layer
from the effects of moisture. In a preferred embodiment, this
multi-layered structure can be used to produce an economical
structure by utilizing relatively inexpensive materials as the bulk
of the structure.
[0070] Another exemplary and non-limiting example of a
multi-layered structure used to manufacture the container of the
present invention would include an inner layer comprising virgin
polyolefinic material. The next outward layer would comprise
recycled container material, known to those skilled in the art as a
"regrind" layer. The next layers would comprise a thin layer of
adhesive, the barrier layer, and another adhesive layer to bind the
barrier layer to the container. The final outer layer can comprise
another layer of virgin polyolefinic material.
[0071] A further exemplary and non-limiting example of a
multi-layered structure used to manufacture the container of the
present invention would include an inner layer comprising virgin
polyolefinic material. The next layers would comprise a thin layer
of adhesive, the barrier layer, and another adhesive layer to bind
the barrier layer to the container. The next outward layer would
comprise recycled container material, known to those skilled in the
art as a "regrind" layer. The final outer layer can comprise
another layer of virgin polyolefinic material. In any regard, it
should be known to those skilled in the art that other potential
compounds or combinations of compounds, such as polyolefins,
adhesives and barriers could be used. In particular, the inner
layer may be a barrier made from or incorporating an oxygen
barrier, such as nylon, EVOH, or a metallic film. A metallic film,
for example, can be an oxygen barrier and also prevent the coffee
aroma from infiltrating the plastic of the remaining layers of a
multi-layer structure. Further, an oxygen scavenger can be
incorporated into, or on, any layer of a multi-layered structure to
remove any complexed or free oxygen existing within a formed
container. Other oxygen scavengers can include oxygen scavenging
polymers, complexed or non-complexed metal ions, inorganic powders
and/or salts, and combinations thereof, and/or any compound capable
of entering into polycondensation, transesterification,
transamidization, and similar transfer reactions where free oxygen
is consumed in the process.
[0072] Another exemplary and non-limiting example of a
multi-layered structure used to manufacture the container of the
present invention includes use of a collapsible inner layer, such
as a bag-like structure 80 shown in FIG. 16. In this embodiment,
the bag 80 is inserted into a container 82 having an upper edge 84.
In one embodiment, the upper edge 86 of the bag 80 is sealed to the
upper edge 84 of the container 82, such as by an adhesive or a heat
seal. Then coffee or other stored product is placed into the bag
80, and the bag 80 may optionally be sealed closed. In another
embodiment, the bag 80 can be filled with material and sealed prior
to being placed inside the plastic container 82. In either case,
the bag 80 can have a one-way valve disposed thereon, and can
expand in response to the off-gassing of the packaged product, if
necessary, without necessarily causing the outer plastic container
82 to expand. Likewise, the bag 80 can be compressed independently
of the outer plastic container 82. As such, the bag 80 can deform
and change volume with changing pressure differentials, leaving the
outer plastic container 82 relatively unchanged by such pressure
differentials. The bag 80 may also be used in a vacuum-packing
arrangement of the product within the bag 80. Such a bag 80 may be
used in conjunction with a lid having a one-way valve, as well as
an overcap, as described in connection with other embodiments. In
this way, the bag 80 functions as a region of deflection to
compensate for changes in pressure within the container 84. The bag
80 may be made from any other suitable material. The container 82
may be like the other containers disclosed herein, having its own
region of deflection in addition to the bag-like structure.
[0073] The bag 80 may also or alternatively be initially laminated
or otherwise non-permanently attached along all or part of its
outer surface 88 to the inner surface 90 of the container 82. Then,
if a sufficient underpressure arises within the container 82, the
bag 80 may become detached from the container 82. In this way, the
exterior appearance of the container 82 does not change, and
instead maintains its shape. When the end user opens the container
82, the resulting pressure equalization with the outside atmosphere
causes the bag 80 to expand to the inner surface 90 and fill the
interior of the container 82.
[0074] In yet another embodiment shown in FIGS. 17A and 17B, a
container 100 has a region of deflection comprising an
accordion-like expandable portion 102. In this embodiment, coffee
or other off-gassing product is disposed within the container 100
in a collapsed condition, as shown in FIG. 17A. As the packaged
product emits gas, the container 100 may expand to a condition such
as shown in FIG. 17B. In this way, the height of the container 100
changes to compensate for changes in pressure within the container
100. The container 100 may additionally be used with a one-way
valve, as described with respect to other embodiments.
[0075] Other such materials and processes for container formation
are detailed in The Wiley Encyclopedia of Packaging Technology,
Wiley & Sons (1986), herein incorporated by reference.
Preferably, the inner layer of the container is constructed from
high-density polyethylene (HDPE).
[0076] A preferred polyolefinic, blow molded container in
accordance with the present invention can have an ideal minimum
package weight for the round containers of FIGS. 1 and 7, or the
parallelepiped container of FIG. 2, and yet still provide the top
load characteristics necessary to achieve the goals of the present
invention. Exemplary materials (low-density polyethylene (LDPE),
high density polyethylene (HDPE) and polyethylene terephthalate
(PET)) and starting masses of these compounds that provide
sufficient structural rigidity in accordance with the present
invention are detailed in Table 1:
TABLE-US-00001 TABLE 1 Package Shape and Weight For a Given
Material and a Defined Top Load (Empty) for a Nominal 3.0 L
Container Package Material & Tensile Package Weight Package
Weight Package Modulus 35 lb. 120 lb. Configuration (psi/atm) Top
Load (grams) Top Load (grams) Parallelepiped LDPE 79 grams 146
grams (40,000/2,721) Parallelepiped HDPE 66 grams 123 grams
(98,000/6,669) Parallelepiped PET 40 grams 74 grams
(600,000/40,828) Round LDPE 51 grams 95 grams (40,000/2,721) Round
HDPE 43 grams 80 grams (98,000/6,669) Round PET 26 grams 48 grams
(600,000/40,828)
[0077] It was surprisingly found that a container in accordance
with the present invention that is filled with product and sealed
to contain the final product has enhanced properties for the same
starting compound weight. This provides a benefit in that it is now
possible to use less starting material to provide the top load
values in accordance with the present invention. Exemplary
materials and starting masses of compounds (LDPE, HDPE, and PET)
providing the necessary structural rigidity of a filled and sealed
container in accordance with the present invention are detailed in
Table 2:
TABLE-US-00002 TABLE 2 Package Shape and Weight For a Given
Material and a Defined Top Load (Filled) for a Nominal 3.0 L
Container Package Material & Tensile Package Weight Package
Weight Package Modulus 35 lb. 120 lb. Configuration (psi/atm) Top
Load (grams) Top Load (grams) Parallelepiped LDPE 72 grams 134
grams (40,000/2,721) Parallelepiped HDPE 61 grams 112 grams
(98,000/6,669) Parallelepiped PET 37 grams 68 grams
(600,000/40,828) Round LDPE 47 grams 87 grams (40,000/2,721) Round
HDPE 39 grams 73 grams (98,000/6,669) Round PET 24 grams 44 grams
(600,000/40,828)
[0078] Again referring to FIG. 1, protuberance 17, in the form of a
rim like structure, disposed at the open end of container 11 may
have textured surfaces disposed thereon. Textured surfaces disposed
on protuberance 17 can comprise raised surfaces in the form of
protuberances, annular features, and/or cross-hatching to
facilitate better sealing of removable closure 19. Exemplary, but
non-limiting, annular features may include a single bead or a
series of beads as concentric rings protruding from the seal
surface of protuberance 17. While not wishing to be bound by
theory, it is believed that a textured surface on protuberance 17
can allow for the application of a more uniform and/or concentrated
pressure during a sealing process. Textured surfaces can provide
increased sealing capability between protuberance 17 and removable
closure 19 due to any irregularities introduced during molding,
trimming, shipping processes and the like during manufacture of
container 11.
[0079] In addition, the bottom portion 13 or the body portion 14 of
the container 11 may include a one-way valve, such as the valve 20
discussed further below in connection with the removable closure
18. Alternatively, a valve disposed in or on the structure of the
container 11 may be a more rigid one-way mechanical valve, as well
known in the art, rather than the soft valve 20. One of ordinary
skill will know of various valve structures which would be suitable
for this purpose.
The Removable Closure
[0080] Again referring to FIG. 1, fresh packaging system 10
comprises a closure 18 that is a laminated, peelable seal 19 that
is removably attached and sealed to container 11. Peelable seal 19
has a hole beneath which is applied a degassing valve, indicated as
a whole by reference number 20. One-way valve 20 can be heat welded
or glued to peelable seal 19.
[0081] In a preferred embodiment according to FIG. 3, the interior
of peelable seal 19 to the outer side of peelable seal 19 is a
laminate and comprises, in sequence, an inner film 21, such as
polyethylene, a barrier layer 22, such as a metallized sheet,
preferably metallized PET, metallized PE, or aluminum, and an outer
film of plastic 23, such as PET. Inner film 21 is preferably formed
from the same material as the outer layer of container 11. Thus,
inner film 21 is preferably a polyolefin, and more preferably
polyethylene (PE). Plastic outer film 23 is preferably produced
from a material such as polyester. However, one skilled in the art
would realize that other materials, such as a foil closure, and
other stretchable and non-stretchable layer structures can be used
and still remain within the scope of the present invention.
Additionally, an oxygen scavenger, as described supra, can be
incorporated into, or on, any layer of peelable seal 19 to remove
free, or complexed, oxygen.
[0082] Both inner film 21 and barrier layer 22 are perforated,
preferably by means of cuts, pricks, or stampings, to form flow
opening 24, as shown in FIG. 3. In the area above the outlet
opening, outer film 23 is not laminated to barrier layer 22,
thereby forming longitudinal channel 25. Channel 25 extends the
entire width of the laminate so that during manufacture, channel 25
extends to the edge of closure 18.
[0083] As a result, a very simple and inexpensive one-way valve 20
is formed by means of the non-laminated area of outer film 23 and
outlet opening 24. The gases produced by the contents within
container 11 may flow through valve 20 to the surrounding
environment. Since an overpressure exists in container 11, and
since outer film 23 usually adheres or at least tightly abuts
barrier layer 22 because of the inner pressure, unwanted gases,
such as oxygen, are prevented from flowing into container 11 and
oxidizing the contents. Thus, outer film 23 serves as a membrane
that must be lifted by the inner gas pressure in the packing in
order to release gas. It is preferred that one-way valve 20 opens
in response to pressures developed within container 11. This
opening pressure can exceed 10 millibars, and preferably exceed 15
millibars, and more preferably would exceed 20 millibars, and most
preferably, exceed 30 millibars.
[0084] Additionally, a small amount of liquid can be filled into
channel 25. The liquid can be water, siloxane-based oils, or oil
treated with an additive so that the oil is prevented from becoming
rancid prior to use of the product. The pressure at which the
release of internal off gas from container 11 occurs can be
adjusted by varying the viscosity of the liquid within channel
25.
[0085] In an alternative, but non-limiting, embodiment, a one-way
degassing valve can comprise a valve body, a mechanical valve
element, and a selective filter as described in U.S. Pat. No.
5,515,994, herein incorporated by reference.
[0086] In another embodiment, the container 11, or the closure 18
can have more than one vent valve operatively associated therewith.
For example, in one embodiment, closure 18 can have a one-way
degassing valve as described above, and another one-way valve
configured to permit air to enter the container in the event the
vacuum inside the container exceeds a predetermined level. In this
manner, the second one-way valve can prevent the container from
collapsing if, after overpressure due to altitude changes or
outgassing the container experiences a reverse pressure
differential. This condition is common when shipping packaged
coffee over high elevations, for example. In one embodiment two
one-way valves can be utilized. In another embodiment a single
valve designed to vent in and out, but in and out being vented at
different, predetermined pressures, can be utilized.
[0087] Returning to FIG. 1, closure 18 is preferably sealed to
container 11 along a rim (protuberance) 17 of container 11.
Preferable, but non-limiting, methods of sealing include a heat
sealing method incorporating a hot metal plate applying pressure
and heat through the closure material and the container rim,
causing a fused bond. The peel strength achieved is generally a
result of the applied pressure, temperature, and dwell time of the
sealing process. However, it should be known to one skilled in the
art, that other types of seals and seal methods could be used to
achieve a bond with sufficient and effective seal strength,
including, but not limited to, a plurality of annular sealing beads
disposed on rim 17.
[0088] Alternatively, if protuberance 17 is provided in at least a
substantially outwardly facing orientation from body portion 14 and
substantially perpendicular to the longitudinal axis of container
10, protuberance 17 can be supported during the sealing process.
Providing support in this manner can allow for a seal to be applied
in less overall time through the use of higher temperature and
pressure than would be possible if the protuberance were
unsupported. It is also believed that supporting protuberance 17
during the sealing process can result in a higher quality seal,
provide less variation in the seal, and provide a more consistent
peel force. It is also believed that supporting protuberance 17
during a sealing process can reduce the time necessary to provide
such seals resulting in lower production costs.
[0089] As shown in FIG. 8, in an alternative embodiment, peelable
seal 19c of container 11c can include a pivotable pouring device
50. Pivotable pouring device 50 can be placed at any location on
peelable seal 19a or at any position on container 11c. In a
preferred embodiment, it is also believed that pivotable pouring
device 50 could be disposed on a non-peelable seal located under
peelable seal 19c in the interior volume of container 11c. This
could enable a user to remove peelable seal 19c, exposing the
non-peelable seal having the pivotable pouring device 50 disposed
thereon. The user could then pivot the pivotable pouring device 50
to dispense a product contained within container 11c. After
dispensing the product from container 11c via pivotable pouring
device 50, the user could pivot the pivotable pouring device 50 to
effectively close non-peelable seal, thereby effectively sealing
container 11c. As would be known to one of skill in the art, an
exemplary, but non-limiting, example of a pivotable pouring device
50 includes a pouring spout. It is believed that pivotable pouring
device 50 could have dimensions that facilitate the flow of product
from container 11c, as would be known to one of skill in the art. A
depression, slot, or other orifice can be disposed on either
peelable seal 19c or the non-peelable seal to facilitate insertion
of a user's appendage or other device to aid in the application of
force necessary to pivot pivotable pouring device 50.
[0090] In the alternative embodiment of FIG. 8A, a striker bar 52,
formed from either a portion of peelable seal 19d or a non-peelable
seal, can be used to strike off excess product from a volumetric
measuring device. Without wishing to be bound by theory, it is
believed that striker bar 52 could facilitate more consistent
measurements of product by increasing the packing density and
volume present within the volumetric measurement device. Further,
it is believed that the presence of the remainder of peelable seal
19d or a non-peelable seal can assist in the retention of the
various aromatic and non-aromatic gasses that naturally evolute
from a product held within container 11d.
The Overcap
[0091] Referring to FIGS. 1 and 4 to 6, fresh packaging system 10
optionally comprises an overcap 30 comprised of dome portion 31,
skirt portion 32, rib 33, and optionally vent 34. As a non-limiting
example, overcap 30 is generally manufactured from a plastic with a
low flexural modulus, for example, linear low-density polyethylene
(LLDPE), low-density polyethylene (LDPE), high-density polyethylene
(HDPE), polyethylene (PE), polypropylene (PP), polycarbonate,
polyethylene terephthalate (PET), polystyrene, polyvinyl chloride
(PVC), co-polymers thereof, and combinations thereof. This allows
for an overcap 30 that has a high degree of flexibility, yet, can
still provide sufficient rigidity to allow stacking of successive
containers. By using a flexible overcap 30, mechanical application
during packaging as well as re-application of overcap 30 to
container 11 after opening by the consumer is facilitated. A
surprising feature of a flexible overcap 30 is the ability of the
end user to "burp" excess atmospheric gas from container 11 thereby
reducing the amount of oxygen present. Further, an oxygen
scavenger, as described supra, can be incorporated into, or on, any
layer of peelable seal 19 to remove free, or complexed, oxygen.
Additionally, the desired balance of flexibility and rigidity
exhibited by overcap 30 may be achieved by varying the thickness
profile of the overcap 30. For example, the dome portion 31 can be
manufactured to be thinner than skirt portion 32 and rib 33.
[0092] Dome portion 31 is generally designed with a curvature, and
hence height, to accommodate for an outward displacement of closure
18 from container 11 as a packaged product, such as roast and
ground coffee, off gases. The amount of curvature needed in dome
portion 31 can be mathematically determined as a prediction of
displacement of closure 18. As a non-limiting example, a nominal
height of dome portion 31 can be 0.242 inches (0.61 cm) with an
internal pressure on closure 18 of 15 millibars for a nominal
6-inch (15.25 cm) diameter overcap. Further, the dome portion 31 is
also generally displaceable beyond its original height as internal
pressure rises in container 11, causing closure 18 to rise prior to
the release of any off gas by one-way valve 20.
[0093] As shown in the exemplary embodiment of FIG. 9A, stand-off
67 can be provided on the underside of overcap 30b to facilitate
the release of an off gas that may be present within a container.
In this way, stand-off 67 can prevent blockage of a valve disposed
on and/or within a flexible film closure by lower portion 65 of
overcap 30b by reducing the amount of contact of the valve with
lower portion 65. Stand-off 67 can be constructed in various
designs including but not limited to a singular, or plurality of,
arcuate forms, circles, rectangles, lines, and combinations
thereof. Preferably, a circular stand-off 67 is positioned in a
region central to lower portion 65 of overcap 30b. It is believed
that stand-off 67 can also facilitate the venting of gasses
internal to a container. Another such exemplary stand-off 67 is
shown in FIG. 13 as a plurality of annular sections 68, wherein
each annular section 68 is provided with an opening 69 wherein the
plurality of openings 69 provides a path for venting of gasses
internal to container 11f.
[0094] Referring to FIG. 4, overcap 30 comprises a rib 33. Rib 33
protrudes outwardly from the generally planar dome portion 31 and
serves as a physical connection between dome portion 31 and skirt
32. Generally, skirt 32 has a hook shape for lockingly engaging
protuberance 17 of container 11. Rib 33 isolates skirt 32 from dome
portion 31, acting as a cantilever hinge so that outward
deflections (O) of dome portion 31 are translated into inward
deflections (I) of skirt 33. This cantilevered motion provides for
an easier application of overcap 30 to container 11 and serves to
effectively tighten the seal under internal pressures.
[0095] Additionally, rib 33 can allow for successive overcaps to be
stacked for shipping. Skirt 32 preferably has a flat portion near
the terminal end to allow for nesting of successive overcaps.
Furthermore, rib 33 can extend sufficiently away from dome portion
31 so that successive systems may be stacked with no disruption of
the stack due to a maximum deflection of closure 18 and the dome
portion 31 of overcap 30. Without desiring to be bound by theory,
it is believed that the downward load force rests entirely on rib
33 rather than across dome portion 31. Resting all downward forces
on rib 33 also protects closure 18 from a force opposing the
outward expansion of closure 18 from container 11 due to the off
gas generated by a contained product.
[0096] As shown in FIG. 5, an exploded view of the region around
rib 33, dome portion 31 correspondingly mates with protuberance 17
of container 11. As a non-limiting example, container 11, after
opening, requires replacement of overcap 30. A consumer places
overcap 30 on container 11 so that an inside edge 34 of rib 33
contacts protuberance 17. A consumer then applies outward pressure
on skirt 32 and downward pressure on dome portion 31, expectorating
a majority of ambient air entrapped within the headspace of
container 11. As shown in FIG. 6, the inside edge 34 of rib 33 then
fully seats on protuberance 17, producing a complete seal. In a
non-limiting example, protuberance 17 varies from -5.degree. to
+5.degree. from a line perpendicular to body 14. Inside edge 34 is
designed to provide contact with protuberance 17 for this
variation. As another non-limiting example, overall travel of the
inside edge 34 of rib 33 has been nominally measured at three
millimeters for a protuberance 17 width of four to six millimeters.
It has been found that when protuberance 17 is angularly disposed,
protuberance 17 forms a sufficient surface to provide for sealing
adhesive attachment of closure 18 to protuberance 17.
[0097] Additionally, the inside edge 34 of rib 33 can effectively
prevent the pollution of protuberance 17, with or without closure
18 in place, thereby providing a better seal. As pressure within
container 11 builds due to off gas from the entrained product, dome
portion 31 of overcap 30 deflects outward. This outward deflection
causes the inside edge 34 of rib 33 to migrate toward the center of
container 11 along protuberance 17. This inward movement results in
a transfer of force through rib 33 to an inward force on skirt
portion 32 to be applied to container wall 14 and the outer portion
of protuberance 17, resulting in a strengthened seal. Additionally,
significant deflections of dome 31 due to pressurization of closure
18 causes the inside edge 34 to dislocate from protuberance 17
allowing any vented off gas to escape past protuberance 17 to the
outside of overcap 30. This alleviates the need for a vent in
overcap 30.
[0098] As shown in FIG. 9, an alternative embodiment of overcap 30b
comprises a plurality of nested cylindrical formations. In other
words, in this alternative embodiment, the base of overcap 30b,
having a diameter, d, forms a base portion 60 upon which the upper
portion 62 of overcap 30b, having a diameter, d-.DELTA.d, is
disposed thereon. The upper portion 62 of overcap 30b can have an
annular protuberance 64 disposed thereon. It is believed that the
annular protuberance 64 disposed upon the upper portion 62 of
overcap 30b can provide a form upon which annular ring 42 disposed
upon closed bottom 13, can lockably nest.
[0099] In another embodiment, it has been found advantageous to
limit .DELTA.d. A small .DELTA.d can result in the connecting wall
63 of overcap 30b being proximate to protuberance 17. Providing a
small .DELTA.d in this manner can facilitate the transfer of a
force exerted by a load disposed upon overcap 30 to an attached
container during storage and shipping.
[0100] As shown in FIGS. 9A and 10, in an alternative embodiment,
the inner surface of the base portion 60 of overcap 30b can have an
annular sealing ring 66 disposed thereon. Annular sealing ring 66
was surprisingly found to facilitate the mating of surfaces
corresponding to annular sealing ring 66 and the finish portion of
container 11. Mating the surfaces in this manner can provide an
audible recognition that both surfaces have made contact and that a
secure seal between protuberance 17 and the internal surface of
overcap 30b has been made. A surprising feature of overcap 30b is
the ability of the end user to "burp" excess atmospheric gas from
container 11 thereby reducing the amount of oxygen present.
Further, it is believed that an inner surface of base portion 60
mate with at least a portion of protuberance 17 so that there is
provided an overlap of the inner surface of base portion 60 with
protuberance 17. One of skill in the art would realize that any
configuration of the annular sealing ring 66 may be used to provide
the facilitation of the corresponding mating surfaces, including,
but not limited to, interrupted annular rings, a plurality of
protuberances, and combinations thereof. It is also believed that
providing a protuberance 69 in the form of an annular ring,
plurality of protuberances, and other protuberances known to one of
skill in the art, can provide a method of stacking a plurality of
overcaps 30b prior to overcap 30b being applied to a container.
[0101] As shown in FIG. 9A, it was surprisingly found that a
plurality of protuberances 68 disposed upon the inner surface of
overcap 30b could facilitate the replacement of overcap 30b upon
container 11. In this manner, it is believed that the plurality of
protuberances 68 disposed upon the inner surface of overcap 30b can
effectively translate the horizontal component of a force applied
to overcap 30b during replacement of overcap 30b upon container 11
through the plurality of protuberances 68 thereby allowing the
plurality of protuberances 68 to effectively traverse over the edge
of container 11 and ultimately aligning the longitudinal axis of
overcap 30b with the longitudinal axis of container 11. Further, a
plurality of protuberances 68 disposed upon the inner surface of
overcap 30b can also provide additional structural rigidity to
overcap 30b and can increase the transfer efficiency of a force
exerted by a load disposed upon overcap 30b to container 11. It
would be realized by one of skill in the art that the plurality of
protuberances 68 could comprise a plurality of spherical,
semi-spherical, elliptical, quarter-round, and polygonal
projections, indentations, and combinations thereof.
[0102] In an alternative embodiment as shown in FIG. 13, container
11f can be provided with at least one secondary protuberance 74
disposed upon body portion 14. In this way, overcap 30c can be
provided with an elongate skirt portion 72 with annular sealing
ring 66a disposed thereon. Thus, annular sealing ring 66a can be
removably engaged with secondary protuberance 74 to provide a
better engagement of overcap 30c to container 11f. Without desiring
to be bound by theory, it is believed that a container 11f provided
with a protuberance 17a will exhibit a rotational movement about
axis 76 due to a vacuum internal to container 11f and/or a load
disposed upon protuberance 17a thereby causing protuberance 17a to
move away from overcap 30c. Thus, providing secondary protuberance
74 along body portion 14 away from axis 76 can provide a point of
interaction between overcap 30c and container 11f that is subject
to less movement. Secondary protuberance 74 can be provided as an
annular ring, a plurality of individual protuberances or a
plurality of collectively elongate protuberances. Elongate skirt
portion 72 can be provided as an annular protuberance or a
collectively annular plurality of separable segments. Further,
elongate skirt portion 72 can be provided in any length to
facilitate attachment of overcap 30c to secondary protuberance 74
disposed upon body portion 14.
[0103] In yet another embodiment as shown in FIG. 18, a container
11g is provided with a top opening 12g. The top opening 12g is
disposed at an angle relative to the vertical axis VA of the
container 11g as it rests on a level surface. A seal (not shown in
FIG. 18) similar to the seal 19 shown in FIG. 1 may be used with
the container 11g of FIG. 18. Also, an overcap 30d substantially
similar to the overcap 30, the overcap 30b or the overcap 30c may
be used in conjunction with the container 11g, using an
appropriately structured protuberance 17g as shown in connection
with those overcaps 30, 30b or 30c. In this way, the structure and
operation of the embodiment shown in FIG. 18 is substantially the
same as in other embodiments, except that the opening 12g is
disposed at an angle with respect to the vertical axis VA.
Similarly, other containers may have openings disposed in a side
surface, a bottom surface, or any other surface.
Coffee Packaging
[0104] A preferred method of packaging a whole, roast coffee in
accordance with the present invention to provide a more freshly
packed coffee product, is detailed herein.
[0105] A whole coffee bean is preferably blended and conveyed to a
roaster, where hot air is utilized to roast the coffee to the
desired degree of flavor development. The hot roasted coffee is
then air-cooled and subsequently cleaned of extraneous debris.
[0106] In a preferred, but non-limiting step, a whole roast coffee
is cracked and normalized (blended) before grinding to break up
large pieces of chaff. The coffee is then ground and cut to the
desired particle size for the grind size being produced. The ground
coffee then preferably enters a normalizer that is connected to the
bottom of the grinder heads. In the normalizer, ground coffee is
preferably slightly mixed, thus, improving the coffee appearance.
As another non-limiting step, the coffee discharges from the
normalizer and passes over a vibrating screen to remove large
pieces of coffee.
[0107] The ground coffee is then preferably sent to a filler surge
hopper and subsequently to a filling apparatus (filler). The filler
weighs a desired amount of coffee into a bucket that in turn, dumps
the pre-measured amount of coffee into a container manufactured as
detailed supra. The container is then preferably topped-off with an
additional amount of coffee to achieve the desired target
weight.
[0108] The container is then preferably subjected to an inert gas
purge to remove ambient oxygen from the container headspace.
Non-limiting, but preferred, inert gases are nitrogen, carbon
dioxide, and argon. Optionally, an oxygen scavenger, as described
supra, and generally present in the form of a packet can be
included within the container to provide removal of free or
complexed oxygen. A closure, as disclosed supra, is placed on the
container to effectively seal the contents from ambient air.
Preferably the closure has a one-way valve disposed thereon. An
overcap, disclosed supra, is then applied onto the container,
effectively covering the closure and locking into the container
sidewall ridge. The finished containers are then packed into trays,
shrink wrapped, and unitized for shipping.
Freshness
[0109] It is believed that the resulting inventive packaging system
provides a consumer with a perceptively fresher packed roast and
ground coffee that provides a stronger aroma upon opening of the
package and the perception of a longer-lasting aroma that is
apparent with repeated and sustained openings of the packaging
system. Not wishing to be bound by any theory, it is believed that
roast and ground coffee elutes gases and oils that are adsorbed
onto the polyolefinic compound comprising the inside of the
container and closure. Upon removal of the closure, the
polyolefinic compound then evolutes these adsorbed gases and oils
back into the headspace of the sealed container. It is also
believed that the inventive packaging system can also prevent the
infiltration of deleterious aromas and flavors into the packaging
system. Thus, the construction of the instant packaging system can
be altered to provide the benefit of most use for the product
disclosed therein. To this end, it is further believed that the
packaging system can be utilized for the containment of various
products and yet provide the benefits discussed herein.
[0110] Applicants characterize the surprising aroma benefits
provided by the present article of manufacture in terms of the
article's "overall coffee aroma value", which is an absolute
characterization. Applicants also characterize the aroma benefits
relative to a control article (a prior art metallic can, as
described below). Such a characterization is referred to herein as
the article's "differential coffee aroma value." The methods for
measuring overall coffee aroma value and differential coffee aroma
value are described in detail in the Test Method section infra.
[0111] The article of manufacture will have an overall coffee aroma
value of at least about 5.5. Preferably, the article will have an
overall coffee aroma value of least about 6, more preferably at
least about 6.5, still more preferably at least about 7, and still
more preferably at least about 7.5.
[0112] Preferably, the article of manufacture of the present
invention will have a differential coffee aroma value of at least
about 1.0, more preferably at least about 2.0, and most preferably
at least about 2.8.
Test Method
[0113] A test container and an existing industry standard metallic
container (control container) are packed with identical fresh roast
and ground coffee product, prepared as stated above, and stored for
120 days prior to testing. Immediately prior to testing, the
containers are emptied and wiped with a paper towel to remove
excess roast and ground coffee product. Each container is then
capped and let stand prior to testing in order to equilibrate.
During testing, each container used is exchanged with another
similarly prepared, but, unused container at one-hour intervals. A
control container is a standard 603, tin-plated, 3-pound (1.36 Kg),
vacuum-packed, steel can.
[0114] Individual panelists are screened for their ability to
discriminate odors utilizing various standard sensory methodologies
as part of their sensory screening. Panelists are assessed for
aroma discriminatory ability using the gross olfactory
acuity-screening test (universal version) as developed by
Sensonics, Inc., for aroma. This test method involves a potential
panelist successfully identifying aromas in a "scratch and sniff"
context.
[0115] Forty successful, qualified panelists are then blindfolded
and each evaluates a test container and a control container. Each
blindfolded panelist smells a first container (either test
container or control container) and rates the aroma on a 1 to 9
point scale (integers only) with reference to the following
description: no aroma (1) to a lot of aroma (9). After a brief
relief period, the blindfolded panelist evaluates the second
container. The range for overall aroma is again assessed by
panelists using the same rating system.
[0116] The panel results for overall coffee aroma value are then
tabulated and statistically evaluated. Standard deviations based on
a Student T statistical test are calculated with 95% confidence
intervals to note where statistically significant differences occur
between the mean values of the two products tested. Exemplary and
statistically adjusted results of a "blind test" panel using
existing packaging methodologies for roast and ground coffee are
tabulated in Table 3:
TABLE-US-00003 TABLE 3 Roast and Ground Coffee Sensory Panel
Results for Comparing Inventive Articles vs. Existing Articles at
120 days at 70.degree. F. (21.degree. C.) Standard Steel Package
Inventive Package (Plastic) (Control) No. Respondents 40 40 Amount
of 7.3 4.5 Coffee Aroma
[0117] Based upon this test panel, it was surprisingly found that
the present articles of manufacture provide a perceived "fresher"
roast and ground coffee end product for a consumer. The improvement
in overall coffee aroma was increased from the control sample
adjusted panel value of 4.5 to an adjusted panel value of 7.3 for
the inventive article, resulting in a differential adjusted value
of 2.8.
[0118] While particular embodiments of the present invention have
been illustrated and described, it will be obvious to those skilled
in the art that various changes and modifications may be made
without departing from the spirit and scope of the invention. One
skilled in the art will also be able to recognize that the scope of
the invention also encompasses interchanging various features of
the embodiments illustrated and described above. For example, the
overcap of one illustrated embodiment might be used with a
container of another illustrated embodiment. Also, what is shown or
described as one single part may be made from multiple parts which
are connected to together. For example, the body portion 14 as
shown in FIG. 4 may be made from two different parts, a bottom part
which is purely cylindrical and a top part which forms the
protuberance 17. Accordingly, the appended claims are intended to
cover all such modifications that are within the scope of the
invention.
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