U.S. patent application number 14/071370 was filed with the patent office on 2015-05-07 for fluid injection system and method for scavenging oxygen in a container.
This patent application is currently assigned to Silgan White Cap LLC. The applicant listed for this patent is Silgan White Cap LLC. Invention is credited to Kevin W. Orth, Dennis Szczesniak, James M. Taber.
Application Number | 20150121807 14/071370 |
Document ID | / |
Family ID | 53005922 |
Filed Date | 2015-05-07 |
United States Patent
Application |
20150121807 |
Kind Code |
A1 |
Taber; James M. ; et
al. |
May 7, 2015 |
FLUID INJECTION SYSTEM AND METHOD FOR SCAVENGING OXYGEN IN A
CONTAINER
Abstract
A method and system for injecting fluid into a sealed container
that contains a consumable product is provided. The container is
filled with a consumable product and then sealed with a closure. A
fluid is injected through the closure into the container cavity
after filling and sealing. The fluid increases the internal
pressure of the container and scavenges oxygen in the
container.
Inventors: |
Taber; James M.; (Aurora,
IL) ; Orth; Kevin W.; (Des Plaines, IL) ;
Szczesniak; Dennis; (Lemont, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Silgan White Cap LLC |
Downers Grove |
IL |
US |
|
|
Assignee: |
Silgan White Cap LLC
Downers Grove
IL
|
Family ID: |
53005922 |
Appl. No.: |
14/071370 |
Filed: |
November 4, 2013 |
Current U.S.
Class: |
53/431 ; 53/111R;
53/432 |
Current CPC
Class: |
B65B 31/08 20130101;
B65B 31/047 20130101; B65B 31/006 20130101; B65B 7/28 20130101;
B65B 55/02 20130101 |
Class at
Publication: |
53/431 ; 53/432;
53/111.R |
International
Class: |
B65B 31/00 20060101
B65B031/00; B65B 31/08 20060101 B65B031/08; B65B 7/16 20060101
B65B007/16; B65B 39/00 20060101 B65B039/00; B65B 55/00 20060101
B65B055/00 |
Claims
1. A fluid injection method for a container that contains a
consumable product comprising: providing a container including a
cavity and an opening providing access to the cavity; providing a
closure, wherein at least one of the container and the closure
contains a redox catalyst; filling the container cavity through the
opening with a consumable product; sealing the container opening
with the closure; and injecting a fluid through the closure into
the container's cavity after sealing, wherein the fluid acts to
pressurize the container and to scavenge oxygen from the contents
of the container.
2. The method of claim 1 wherein the injected fluid has a
percentage composition of hydrogen greater than 0.1%.
3. The method of claim 2 wherein the injected fluid is pure
hydrogen.
4. The method of claim 2 wherein the injected fluid is a mixture of
hydrogen and nitrogen.
5. The method of claim 2 wherein the fluid is a gas.
6. The method of claim 2 wherein the fluid is a liquid.
7. The method of claim 1 wherein the container is permeable to
molecular oxygen.
8. The method of claim 7 wherein the container is made from
blow-molded thermoplastic.
9. The method of claim 1 wherein the injection of a fluid occurs
via a nozzle, the method further comprising: piercing the closure
with the nozzle prior to injection of the fluid; and removing the
nozzle from the closure after the injecting the fluid.
10. The method of claim 9 wherein piercing the closure creates a
hole through the closure, and the method further comprising:
sealing the hole in the closure.
11. The method of claim 10 wherein a material of the closure is
configured to self-seal, wherein the sealing of the hole is
accomplished by the self-sealing of the material of the
closure.
12. The method of claim 1 wherein the redox catalyst includes a
compound containing a Group VIII metal or a molecule containing a
Group VIII metal.
13. A fluid injection method for a sealed container that is
permeable to molecular oxygen and that contains a consumable
product comprising: providing a container permeable to molecular
oxygen including an opening providing access to the contents of the
cavity of the container; providing a thermoplastic closure
including a top panel, a skirt extending downward away from the top
panel and a thermoplastic elastomer liner coupled to a lower
surface of the top panel, wherein at least one of the container,
closure and liner includes a catalyst material; filling the cavity
of the container through the opening with a consumable product;
sealing the opening of the container with the closure; then
inserting a nozzle through the closure and through the
thermoplastic elastomer liner into the cavity of the plastic
container; injecting a fluid via the nozzle into the container's
cavity after filling and sealing; and removing the nozzle from the
closure and thermoplastic elastomer liner, wherein the
thermoplastic elastomer liner self-seals forming a hermetic seal,
and wherein the fluid acts to pressurize the container and to bind
oxygen from the contents of the container.
14. The method of claim 13 wherein the injected fluid has a
percentage composition of hydrogen greater than 0.1%.
15. The method of claim 14 wherein the injected fluid is pure
hydrogen.
16. The method of claim 14 wherein the injected fluid is a mixture
of hydrogen and nitrogen.
17. The method of claim 13 wherein the insertion of the nozzle
includes piercing at least one of the closure and the liner.
18. A system for injecting fluid into a container that contains a
consumable product and that is sealed by a closure, the system
comprising: an injection nozzle; a pressurized fluid source
containing a fluid; a conduit coupling the injection nozzle to the
fluid source; and an actuator coupled to the injection nozzle and
configured to move the injection nozzle toward and away from the
closure sealing the container; wherein the injection nozzle is
configured to inject the fluid through the closure into the
container, and wherein the fluid is configured to change the
internal pressure of the container and react to bind oxygen in the
cavity of the container.
19. The system of claim 18 wherein the injected fluid has a
percentage composition of hydrogen greater than 0.1%.
20. The system of claim 18 wherein the injected fluid is a mixture
of hydrogen and nitrogen.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of
containers. The present invention relates specifically to injection
of a fluid into the container to scavenge oxygen and support the
container wall.
SUMMARY OF THE INVENTION
[0002] One embodiment of the invention relates to a fluid injection
method with the dual purposes of pressurizing a filled, sealed food
or beverage container and scavenging oxygen in the sealed
container. The method includes providing a container having an
opening and cavity. The method includes filling the container
cavity through the opening with a food, beverage or other
consumable product. The method includes sealing the opening with a
closure. The container or the closure may include a material
incorporating a catalyst for the purpose of scavenging oxygen.
[0003] The method then continues by injecting a fluid through the
hermetically sealed closure into the container cavity after filling
and sealing. The injected fluid increases the pressure of the
sealed container. The injected molecular hydrogen, when combined
with the catalyst, scavenges molecular oxygen from the contents of
the container via a chemical reaction.
[0004] Another embodiment relates to a fluid injection method with
the dual purposes of pressurizing a filled, sealed food or beverage
container permeable to molecular oxygen and scavenging oxygen in
the sealed container. The method includes providing a container
permeable to molecular oxygen having an opening and cavity. In
another embodiment, the container may be plastic. The method
includes filling the container cavity through the opening with a
food, beverage or other consumable product. The method includes
providing an injection molded thermoplastic closure, the closure
including a top panel, a skirt extending downward away from the top
panel and a thermoplastic elastomer liner coupled to a lower
surface of the top panel. The method includes sealing the container
opening with the closure, where the container has a first internal
pressure following sealing of the container with the closure.
[0005] The method continues by inserting a nozzle through the
thermoplastic elastomer liner and into the cavity of the plastic
container. The method includes injecting a fluid through the nozzle
into the container cavity after filling and sealing. The injected
fluid may be a combination of one or more inert gases, molecular
hydrogen, and may include one or more other gases. The method
includes removing the nozzle from the cavity of the plastic
container and from the thermoplastic elastomer liner. The
thermoplastic elastomer liner self-seals forming a hermetic seal,
and the container has final internal pressure greater than the
initial internal pressure. The injected molecular hydrogen, when
combined with the catalyst, scavenges molecular oxygen from the
contents of the sealed container via a chemical reaction.
[0006] Another embodiment relates to a system for injecting fluid
into a filled, sealed plastic food or beverage container to
scavenge oxygen and increase the internal pressure of the
container. The system includes an injection nozzle, at least one
fluid source containing a fluid and at least one conduit coupling
the injection nozzle to the at least one fluid source. One of the
one or more fluid sources contains molecular hydrogen. The system
includes at least one gauge and at least one valve coupled to the
conduit to control the flow and pressure of the fluid source. The
system includes an actuator coupled to the injection nozzle and
configured to move the injection nozzle toward a closure sealing
the food or beverage container. The injection nozzle is configured
to inject the pressurizing fluid through the closure into the
plastic beverage container.
[0007] Alternative embodiments relate to other features and
combinations of features as may be generally recited in the
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] This application will become more fully understood from the
following detailed description, taken in conjunction with the
accompanying figures, wherein like reference numerals refer to like
elements in which:
[0009] FIG. 1 is a fluid injection system according to an exemplary
embodiment.
[0010] FIG. 2 shows a method of injecting fluid into a filled
container according to an exemplary embodiment.
[0011] FIG. 3 is a closure used with the system of FIG. 1 according
to an exemplary embodiment.
[0012] FIG. 4 is a closure used with the system of FIG. 1 according
to an exemplary embodiment.
[0013] FIG. 5 is a closure used with the system of FIG. 1 according
to an exemplary embodiment.
[0014] FIG. 6 is a closure used with the system of FIG. 1 according
to an exemplary embodiment.
[0015] FIG. 7 is a closure used with the system of FIG. 1 according
to an exemplary embodiment.
[0016] FIG. 8 is a closure used with the system of FIG. 1 according
to an exemplary embodiment.
[0017] FIG. 9 is a closure used with the system of FIG. 1 according
to an exemplary embodiment.
[0018] FIG. 10 is a closure used with the system of FIG. 1
according to an exemplary embodiment.
[0019] FIG. 11 is a closure used with the system of FIG. 1
according to an exemplary embodiment.
[0020] FIG. 12 is a closure used with the system of FIG. 1
according to an exemplary embodiment.
[0021] FIG. 13 is a closure used with the system of FIG. 1
according to an exemplary embodiment.
DETAILED DESCRIPTION
[0022] Referring generally to the figures, various embodiments of a
method and a system for injecting a fluid (e.g., molecular
hydrogen, a mixture of hydrogen and nitrogen, a mixture of hydrogen
and an inert gas, a mixture of multiple gases with a percentage
composition of hydrogen greater than atmospheric air) into a filled
and sealed container are shown. The fluid can be a liquid, a gas,
or a combination of liquid and gas. The injected fluid may be a
combination of one or more inert gases, molecular hydrogen, and may
include one or more other gases. In another embodiment, the
injected fluid may be pure molecular hydrogen. In addition,
closures configured to facilitate fluid injection are shown.
[0023] In general, a container (e.g., a plastic beverage bottle) is
filled with a solid and/or fluid (e.g., a consumable food or
beverage) and is then sealed by coupling a closure over the filling
opening of the container. At least one of the container and the
closure includes a catalyst (e.g., a redox catalyst). Following
sealing of the container, an injection device injects a fluid
through the closure into the cavity of the container. The injected
fluid increases the pressure within the cavity of the container,
thereby acting to support the container walls against the inwardly
directed forces that the container may experience (e.g., grasp
force of the end user, air pressure, forces due to stacking in
storage and transportation of the filled container). The injected
fluid includes at least some molecular hydrogen that, when in
proximity to the redox catalyst, acts to scavenge oxygen from the
contents of the container via a chemical reaction. The closure used
to seal the container may include one or more elements or features
configured to facilitate injection of the fluid through the
closure.
[0024] In certain thin-walled containers, the containers may be
originally filled with contents at atmospheric pressure, but the
radial strength of the sidewall of the container is too low to
prevent inward buckling of the sidewall when the container is
handled by the end user or during shipping and stacking In
addition, some containers are originally filled with hot or warm
contents, and in such containers the pressure within the sealed
container decreases as the temperature of the contents of the
container cool following sealing by the closure. In these
embodiments, the fluid injected by system acts to support the walls
of the container from the various radially inwardly directed
forces.
[0025] Many foods, beverages, and other consumable products are
oxygen sensitive. The presence of molecular oxygen in containers
for these food and beverage products shortens the shelf life of the
product and can affect the tastes, colors, textures and other
properties of the product. Oxygen may be present in the product, or
it may be present in the gas filling the headspace of the container
at the time the container is sealed. Oxygen may also permeate
certain types of containers commonly used for packaging food and
beverages, such a plastic bottles. For the purposes of this
discussion, permeation of a gas means diffusion of small molecules
through a polymeric matrix by migrating past individual polymer
chains, and is distinct from leakage, which is transport through
macroscopic or microscopic holes in a container structure. Plastic
bottles and other containers can be permeated by a variety of gases
other than oxygen, including hydrogen gas. The selection of certain
materials for food or beverage containers can minimize the
permeability rates of gases.
[0026] Regardless of whether the oxygen was sealed in the container
or permeated the container after sealing, oxygen can be scavenged
from sealed containers using hydrogen and a catalyst to facilitate
a redox chemical reaction. For the purposes of this discussion, a
catalyst is broadly defined as a molecule that facilitates a
chemical reaction without being used up in the chemical reaction.
The catalyst may be incorporated into the material of the
container, the closure, the seal, or any other part that comes into
contact with the container or its contents. The scavenging of
oxygen does not remove it from the contents of the container, but
instead neutralizes its effects on the contents of the container by
combining it with hydrogen to create water molecules (H.sub.2O).
The amount of water created, and consequently the amount of oxygen
scavenged, depends on the amount of hydrogen available to react
with the oxygen present in the food or beverage container.
[0027] The system and methods described herein of pressurizing the
cavity of the container following filling and sealing give the user
greater precision in determining the final pressure of the
container as compared to methods in which the container is
pressurized prior to sealing off the container with the closure.
This precision is an advantage over systems that "flush" with
hydrogen gas, or pump hydrogen gas into an evacuated container
before sealing. Methods that add hydrogen gas before sealing are
imprecise and inefficient. These methods that add hydrogen before
sealing are also less compatible with rotating continuous motion
machinery used in many manufacturing applications. Similarly, it is
believed that the introduction of molecular hydrogen after sealing
the container leads to greater precision in controlling the amount
of hydrogen introduced and consequently in calculating the amount
of oxygen scavenged from the contents of the container. The various
embodiments described herein combine the increase in container
pressure with oxygen scavenging for greater efficiency in
manufacturing.
[0028] Referring to FIG. 1, a fluid injection system 10 is shown
according to an exemplary embodiment. System 10 includes an
injection nozzle, shown as piercing nozzle 12. Nozzle 12 is coupled
to a pressurized fluid supply; in this exemplary embodiment, the
pressurized fluid supply includes two sources of fluid. One fluid
source 15 is molecular hydrogen, while the other fluid source 14
contains fluid to be combined with the molecular hydrogen. Fluid
source 15 is coupled to a gauge 46 and a non-return valve 33 via a
conduit 11, while fluid source 14 is coupled to a gauge 48 and a
non-return valve 31 via a conduit 13. Conduit 13 and conduit 11
join at a coupling device 35, from which conduit 16 emerges and
enters an actuator 18. Actuator 18 is configured to move nozzle 12
toward and away from container 20 in the direction shown by arrow
22. Actuator 18 is configured to drive nozzle 12 downward with
sufficient force to pierce a closure 30 on a filled and sealed
container 20. In various embodiments, actuator 18 is a machine
driven actuator, and in one embodiment, is a hydraulic piston and
in another embodiment is a gas piston.
[0029] As shown in FIG. 1, fluid injection system 10 is configured
to inject fluid into a filled and sealed container 20. In the
embodiment, container 20 as shown includes a cavity 24, and
contents 26 located within cavity 24. Container 20 includes a
sidewall 21, a neck 28, and a closure 30 that is coupled to neck
28. The filling opening located at the upper end of neck 28 of
container 20 is sealed by closure 30 after container 20 is filled
with contents 26. Closure 30 includes a top wall, shown as upper
panel 32 and a skirt 34 extending downward away from and
substantially perpendicular to upper panel 32. Closure 30 includes
at least one thread 38 formed on the inner surface of skirt 34 that
engages the at least one mating thread 36 formed on the outer
surface of the neck 28 of the container 20.
[0030] Closure 30 includes a liner 40 coupled to the lower surface
of upper panel 32 of the closure 30. Liner 40 is formed from a
compliant polymer material capable of forming a liquid and air
tight seal against the upper rim of the neck 28. In various
embodiments, liner 40 is formed from a thermoplastic elastomer
(TPE) material, and upper panel 32 and skirt 34 are formed from a
relatively rigid thermoplastic material (e.g., polypropylene, high
density polyethylene, etc.).
[0031] In one embodiment, container 20 and closure 30 include
materials with a low permeability to molecular hydrogen and/or
molecular oxygen.
[0032] In various embodiments, a catalyst material such as a redox
catalyst may be incorporated into the materials of one or more of
the closure 30, liner 40, sidewall 21, or any other part of the
container 20. For the desired reaction between molecular hydrogen
and molecular oxygen, some embodiments may incorporate compounds
including Group VIII metals as a catalyst material. These catalyst
materials may be molecules or compounds incorporating palladium
(Pd), platinum (Pt), or iron (Fe), but this does not preclude the
use of molecules or compounds incorporating other Group VIII
metals.
[0033] To inject fluid into container 20 using fluid injection
system 10, filled and sealed container 20 is placed beneath nozzle
12 when nozzle 12 is in a retracted position. With container 20 in
place beneath nozzle 12, actuator 18 drives nozzle 12 downward,
piercing upper panel 32 and liner 40 with nozzle 12. In various
embodiments, actuator 18 is a mechanically operated machine
configured to move the tip of nozzle 12 a precise distance to
pierce upper panel 32 and liner 40. Thus, actuator 18 is configured
to move the tip of nozzle 12 at least the combined thickness of
upper panel 32 and liner 40. In various embodiments, actuator 18 is
configured to move the tip of nozzle 12 0.010 inches more than the
combined thicknesses of the panel and liner embodiments discussed
herein. In various embodiments, actuator 18 is configured to move
the tip of nozzle 12 between 0.020 inches and 0.150 inches,
specifically between 0.020 inches and 0.120 inches and more
specifically between 0.020 inches and 0.110 inches.
[0034] As shown in FIG. 1, nozzle 12 passes through upper panel 32
and liner 40, and tip 42 of nozzle 12 is located within cavity 24
following piercing of upper panel 32 and liner 40. Following
insertion, fluid flows through the nozzle 12. In this embodiment,
the fluid originates from fluid source 15 and fluid source 14,
through conduit 11 and conduit 13 where the respective amounts of
fluid from fluid source 15 and fluid source 14 are controlled by
non-return valve 33 and gauge 46 and non-return valve 31 and gauge
48. The fluid mixture emerges from coupling device 35 into conduit
16, where it then enters actuator 18 before progressing through
nozzle 12 and nozzle tip 42 into the container's cavity 24.
[0035] In one embodiment, fluid supply 15 and fluid supply 14 are
pressurized containers of fluids such that opening of non-return
valve 33 and non-return valve 31 allow the fluids from fluid supply
15 and fluid supply 14 to flow into coupling device 35 and then
into conduit 16. In another embodiment, fluid supply 15 and fluid
supply 14 include high pressure pumps or compressors configured to
pressurize the fluids, and in this embodiment the pumps are
configured to pressurize the fluids. In various embodiments,
non-return valve 33 and non-return valve 31 are electronically
controlled valves configured to open following insertion of the
nozzle 12 into container 20. In one such embodiment, non-return
valve 33 and non-return valve 31 are solenoid actuated check valves
controlled by an electronic control system (e.g., one or more
computers, processing circuitry, microprocessors, etc.) that is
configured to control system 10 to provide the functionality
discussed herein.
[0036] In some embodiments, the amount of fluid delivered is a
predetermined combination of amounts of fluids from fluid source 15
and fluid source 14. In alternate embodiments, there may be only
one source of hydrogen as the fluid, or there may be more than two
fluid sources, but in all embodiments the amount of fluid delivered
will be predetermined. In embodiments with more than one fluid
source, the amount of fluid from each fluid source is predetermined
individually, so that the percentage composition of the fluid that
is delivered through conduit 16 into actuator 18 and through nozzle
12 into container 20 is known for all components of the fluid
mixture. Percentage composition may be determined by the
calculating the respective masses of fluid components, the
respective volumes of fluid components, the respective numbers of
molecules or atoms of fluid components, or by any other suitable
manner of calculating the composition of a fluid.
[0037] In various embodiments, the injected fluid may be a
combination of molecules. In this instance, a molecule is defined
as any grouping of two or more atoms bound together with chemical
bonds. Such molecules may include but are not limited to compounds,
where a compound is defined as having two or more atoms of
different chemical elements bound together with chemical bonds.
However, in some embodiments, any combination of fluids forming the
injected fluid does not result in any substantial chemical
reactions between the molecules before injection.
[0038] In various embodiments, the presence of the molecular
hydrogen prior to delivery via the nozzle 12 provides certain
benefits over previous systems in which the hydrogen was generated
via a chemical reaction in the container after the container was
sealed. One drawback of generating the hydrogen via chemical
reaction is that the use of at least one additional active
substance, such as a hydride, can prejudicially contaminate the
contents of the container. In addition to unreacted reactants, the
reaction producing the hydrogen may also produce byproducts, and
may even lead to possible chemical reactions between the reactant
and the contents of the container. The system and methods discussed
herein decrease the number of chemical reactions that must occur to
scavenge oxygen from the contents of the container, thereby
decreasing the complexity of the task and reducing the possibility
of unforeseen complications. The system and methods discussed
herein also increase the precision and predictability of the oxygen
scavenging, because the amount of hydrogen ultimately released in
the container is more precise.
[0039] In one embodiment, system 10 is configured to deliver
approximately 30 cubic centimeters (as measured at standard
temperature and pressure) of fluid into container 20. In that
embodiment, the approximately 30 cubic centimeters of fluid may be
a gas having a percentage composition of approximately 96% nitrogen
and approximately 4% hydrogen. In another such embodiment, the
fluid will be 30 cubic centimeters of a gas having a percentage
composition of approximately 98% nitrogen and approximately 2%
hydrogen. In some embodiments, the gas may have a percentage
composition of between 96% and 99.9% nitrogen, and between 4% and
0.1% hydrogen respectively.
[0040] In an alternate embodiment, the amount of fluid delivered
will be approximately 5 cubic centimeters of hydrogen gas as
measured at standard temperature and pressure. In this embodiment,
the portion of the cavity 24 not filled by contents 26 will not be
a vacuum, but will instead be filled by gas that entered the
container prior to sealing 52. In some embodiments, the amount of
fluid delivered may vary, but the fluid is pure hydrogen.
[0041] In an alternate embodiment, the system 10 is configured to
deliver a mixture of 96% liquid nitrogen and 4% liquid hydrogen
kept at a temperature below the boiling point of either fluid
before delivery to the container 20. In this embodiment, the fluid
is a liquid instead of a gas. In alternate embodiments, the fluid
may have a percentage composition of between 96% and 99.9%
nitrogen, and between 4% and 0.1% hydrogen respectively, but in
this case the fluid is a liquid and not a gas.
[0042] In alternate embodiments, the fluid may have a percentage
composition of nitrogen between 96% and 0%, with the remainder of
the fluid comprised of hydrogen gas.
[0043] In a different set of embodiments, the fluid may be a
combination of atmospheric air and pressurized hydrogen gas. In one
embodiment, the fluid may be greater than or equal to 95% hydrogen,
with the remainder atmospheric air. In another embodiment, the
fluid may be greater than or equal to 75% hydrogen, with the
remainder atmospheric air. In another embodiment, the fluid may be
greater than 4% hydrogen, with the remainder atmospheric air. In
another embodiment, the fluid may be greater than or equal to 0.1%
hydrogen, with the remainder atmospheric air.
[0044] In all of the above embodiments, the proportion of the fluid
that is hydrogen to the proportion of the fluid that is other
components is varied based upon the desired results. The greater
the need for oxygen scavenging, the greater the total amount of
hydrogen that must be delivered into the container. The total
amount of fluid delivered is also varied based upon the desired
results. In various embodiments, the amount of fluid delivered
varies based on the size of container 20 and on the fill level of
contents 26 within container 20. The greater the needed increase in
internal pressure in the container, the greater the total amount of
fluid that must be delivered into the container via system 10. As
discussed above, a lower fill level of contents 26 in the container
24 or the intentional decrease of the internal pressure of the
container 24 prior to sealing will increase the total amount of
fluid required to be delivered by system 10.
[0045] Once the predetermined amount of fluid has been delivered,
nozzle 12 is retracted by actuator 18. With nozzle 12 removed, the
compliant material of liner 40 self-seals forming an air-tight
seal. In various embodiments, a material with the ability to
self-seal is a material capable of reforming an air-tight seal
without application of external energy or external initiation of
the self-sealing process.
[0046] While the disclosure herein relates primarily to screw-top
containers, the systems, structures and methods discussed herein
could be used to inject a pressurizing and oxygen-scavenging fluid
into a wide variety of sealed containers. For example, in one
embodiment, structures and methods discussed herein could be used
to inject a pressurizing and oxygen-scavenging fluid into a
hermetically sealed container with a different closure
configuration (e.g., a juice box or a soft bodied pouch containing
a juice drink or other beverage). Furthermore, the container
material is not limited to plastics, but may include glass, metal,
or a cardboard composite material.
[0047] Referring to FIG. 2, a process 50 for injecting a fluid into
a filled and sealed container is shown according to an exemplary
embodiment. At step 51, a container, such as plastic container 20
discussed above, is filled with a food, beverage, medicine, or
other product to be consumed by the end user. At step 52, the
container 20 is sealed with the contents 26 inside. The container
20 may also contain some gas in the headspace when it is sealed. In
one embodiment, the container is sealed with a closure such as
closure 30 discussed above.
[0048] At step 54, the closure is sterilized prior to injecting
fluid through the closure. Sterilization at step 54 can be
implemented through exposure of the filled container and closure to
UV light, an antiseptic chemical wash (e.g., antimicrobial fluid),
flame, plasma, steam and/or hot water.
[0049] At step 56, the nozzle 12 is inserted through the closure 30
of the container 20 into the cavity 24. The nozzle 12 may be a
needle, or it may be another instrument appropriate for delivering
fluid in a targeted direction. The closure 30 may be specifically
configured to accept the nozzle, as discussed herein.
[0050] At step 58, a pressurizing and oxygen-scavenging fluid is
injected through the closure 30 as discussed above regarding FIG.
1. The fluid is injected in a pre-calculated amount based on the
required final internal pressure of the container 20 and based on
the amount of oxygen that must be scavenged from the contents 26 of
the container 20. In various embodiments, injection 58 occurs via
piercing the top panel of the closure with a needle-like piercing
nozzle or via nozzle engagement with valve in closure.
[0051] At step 60, the nozzle 12 is removed from the cavity 24 of
the container 20 through the closure 30.
[0052] In one embodiment, as the nozzle is removed along the same
path that it entered the container, the material of the liner 40
self-seals creating a hermetic seal that allows the container 20 to
maintain the final internal pressure created by the injection of
the pressurizing and oxygen-scavenging fluid. This is one
embodiment of step 62, the sealing of the hole created by the
insertion of the nozzle 12. It should be noted that in such an
embodiment, an additional step to fill the injection hole at step
62 is not needed to hermetically seal the closure 30 because the
hermetic seal of the container 20 is reformed upon withdrawal of
the piercing nozzle 12.
[0053] In another embodiment, the hole created through the upper
panel of the closure 30 by the nozzle 12 (e.g., the injection hole)
may be sealed by melting the thermoplastic material adjacent to the
hole. In various embodiments, melting may be generated via use of a
laser welding tool, a heat-based welding tool or an ultrasonic
welding tool. In another embodiment of step 62, a melted
thermoplastic or adhesive may be applied to fill or cover the
injection hole. In yet another embodiment at step 62, a label or
sticker may be applied over the injection hole. This label or
sticker may serve purely aesthetic purposes when combined with a
self-sealing material in the liner 40, or may serve a functional
purpose as well by actively sealing the container 20.
[0054] In various embodiments, the system shown in FIG. 1 and the
process shown in FIG. 2 is implemented via automated container
processing equipment. In one specific embodiment, the system shown
in FIG. 1 and the process shown in FIG. 2 is implemented via
rotating continuous motion machinery.
[0055] In various embodiments, the closures of the containers used
in the systems and methods discussed herein include one or more
features configured to facilitate injection of fluid through the
closure into the container. For example, in various embodiments,
the thickness of the relatively rigid thermoplastic top panel of
the closure is made to permit piercing by the piercing nozzle of
the injection system, and/or the thickness of the compliant liner
is made to effectively self-seal to form a hermetic seal upon
withdrawal of the piercing nozzle. In other embodiments, the
closure may include an injection window or area that is a thinned
central portion of the closure top panel made to permit piercing by
the piercing nozzle of the injection system. In other embodiments,
the closure may include an injection window or area that is a
central bore formed through the closure top panel filled with the
compliant liner material made to permit piercing by the piercing
nozzle of the injection system and to provide self-sealing. Various
exemplary embodiments of such closures are shown in FIGS. 3-13.
[0056] Referring specifically to FIG. 3, a closure 80 is shown.
Closure 80 includes a top panel 82 and a skirt 84 extending
downward away from top panel 82. Closure 80 includes a liner 86
coupled to the lower surface of top panel 82. In various
embodiments, liner 86 is formed from a compliant polymer material
that self-seals (e.g., a thermoplastic elastomer material), and
upper panel 82 and skirt 84 are formed from a relatively rigid
thermoplastic material (e.g., polypropylene, high density
polyethylene, etc.). In the embodiment shown, the thickness of top
panel 82 is selected such that the piercing nozzle (e.g., piercing
nozzle 12) is able to easily penetrate through top panel 82. In
various embodiments, the thickness of top panel 82 is substantially
the same across the diameter of closure 80 and is between 0.010
inches and 0.060 inches and more specifically is between 0.020
inches and 0.040 inches. In one embodiment, the thickness of top
panel 82 is substantially the same across the diameter of closure
80 and is 0.050 inches plus or minus 0.003 inches. In another
embodiment, the thickness of top panel 82 is substantially the same
across the diameter of closure 80 and is 0.030 inches plus or minus
0.003 inches. In another embodiment, the thickness of top panel 82
is substantially the same across the diameter of closure 80 and is
0.010 inches plus or minus 0.003 inches
[0057] In the embodiment shown, the thickness of central liner
portion 88 of liner 86 is selected to provide for hermetic
self-sealing upon withdrawal of the piercing nozzle of the fluid
injection system. In various embodiments, the thickness of central
liner portion is between 0.010 inches and 0.110 inches,
specifically 0.010 inches and 0.050 inches, and more specifically
is between 0.010 inches and 0.030 inches. In various embodiments,
the thickness of central liner portion is between 0.020 inches and
0.110 inches, specifically 0.020 inches and 0.100 inches, and more
specifically is between 0.020 inches and 0.080 inches. In one
specific embodiment, the thickness of central liner portion is
0.010 inches plus or minus 0.003 inches. In another specific
embodiment, the thickness of central liner portion is 0.020 inches
plus or minus 0.003 inches. In another specific embodiment, the
thickness of central liner portion is 0.040 inches plus or minus
0.003 inches.
[0058] Referring to FIG. 4, a closure 90 is shown. Closure 90
includes a top panel 92 and a skirt 94 extending downward away from
top panel 92. Closure 90 is substantially the same as closure 80
except for the design of self-sealing liner 96. Liner 96 is formed
from a compliant polymer material that self-seals (e.g., a
thermoplastic elastomer material). Liner 96 includes a thin outer
portion 98 and a thick central portion 100. Thick portion 100 of
liner 96 is centrally located below the central region of top panel
92 through which the injection nozzle passes. Thick portion 100 is
thickened in the region of piercing to provide improved
self-sealing of liner 96.
[0059] In various embodiments, the thickness of thickened liner
portion 100 is between 0.015 inches and 0.060 inches, and more
specifically is between 0.020 inches and 0.050 inches. In one
specific embodiment, the thickness of liner portion 100 is 0.020
inches plus or minus 0.003 inches. In another specific embodiment,
the thickness of liner portion 100 is 0.030 inches plus or minus
0.003 inches. In another specific embodiment, the thickness of
liner portion 100 is 0.040 inches plus or minus 0.003 inches. In
one embodiment, the thickness of central liner portion 100 is more
than twice the thickness of outer liner portion 98. In various
embodiments, the thickness of thickened liner portion 100 is
between 0.010 inches and 0.110 inches, specifically 0.010 inches
and 0.050 inches, and more specifically is between 0.010 inches and
0.030 inches. In various embodiments, the thickened liner portion
100 is between 0.020 inches and 0.110 inches, specifically 0.020
inches and 0.100 inches, and more specifically is between 0.020
inches and 0.080 inches.
[0060] Referring to FIG. 5, a closure 110 is shown. Closure 110
includes a top panel 112, a skirt 114 extending downward away from
top panel 112, and a liner 116. Liner 116 includes a thin outer
portion 118 and liner center portion 120. Closure 110 is
substantially the same as closure 90 except for the thickness of
top panel 112. As shown in FIG. 5, top panel 112 is thinner
relative to the liner center portion 120 than the corresponding
portions of closure 90. In this embodiment, top panel 112 has
substantially the same thickness as liner center portion 120. In
various embodiments, the thickness of top panel 112 and of liner
center portion 120 are substantially the same as each other (e.g.,
within 0.003 inches of each other), and the thickness of both is
between 0.015 inches and 0.060 inches, and more specifically is
between 0.015 inches and 0.050 inches. In one specific embodiment,
the thickness of both top panel 112 and liner center portion 120 is
0.020 inches plus or minus 0.003 inches. In another specific
embodiment, the thickness of both top panel 112 and liner center
portion 120 is 0.030 inches plus or minus 0.003 inches. In another
specific embodiment, the thickness of both top panel 112 and liner
center portion 120 is 0.010 inches plus or minus 0.003 inches.
[0061] Referring to FIG. 6, a closure 130 is shown. Closure 130
includes a top panel 132, a skirt 134 extending downward away from
top panel 132, and a liner 136. Closure 130 is substantially the
same as closure 80 shown in FIG. 3 except that top panel 132
includes a thinned central portion 138. Relative to the lower
surface of top panel 132, thinned central portion 138 is a recess
formed at the center of top panel 132. As shown, the lower surface
of liner 136 is substantially planar, however a central portion 140
of liner 136 is thicker than outer portion 142, and central portion
140 fills in the recess formed by the thinned central portion
138.
[0062] In various embodiments, the thickness of thinned central
portion 138 is less than one half the thickness of the outer
portion of top panel 132. In such embodiments, the thickness of
central portion 138 is between 0.005 inches and 0.040 inches, and
more specifically is between 0.005 inches and 0.025 inches. In one
embodiment, the thickness of central portion 138 is 0.020 inches
plus or minus 0.003 inches. In another embodiment, the thickness of
central portion 138 is 0.010 inches plus or minus 0.003 inches.
[0063] In various embodiments, the thickness of central liner
portion 140 is between 0.015 inches and 0.060 inches, and more
specifically is between 0.015 inches and 0.050 inches. In one
specific embodiment, the thickness of central liner portion 140 is
0.020 inches plus or minus 0.003 inches. In another specific
embodiment, the central liner portion 140 is 0.030 inches plus or
minus 0.003 inches. In another specific embodiment, the thickness
central liner portion 140 is 0.040 inches plus or minus 0.003
inches. In one embodiment, the thickness of central liner portion
140 is more than twice the thickness of outer liner portion 142. In
various embodiments, the thickness of central liner portion 140 is
between 0.010 inches and 0.110 inches, specifically 0.010 inches
and 0.050 inches, and more specifically is between 0.010 inches and
0.030 inches. In various embodiments, the central liner portion 140
is between 0.020 inches and 0.110 inches, specifically 0.020 inches
and 0.100 inches, and more specifically is between 0.020 inches and
0.080 inches.
[0064] Referring to FIG. 7, a closure 150 is shown. Closure 150
includes a top panel 152, a skirt 154 extending downward away from
top panel 152, and a liner 156. Closure 150 is substantially the
same as closure 130 shown in FIG. 6 except that top panel 152
includes a central bore 158. Liner 156 includes a central portion
160 that extends through the central bore 158 such that the outer
surface of central liner portion 160 is substantially coplanar with
the outer surface of top panel 152. This embodiment provides a
central window or passage filled with the compliant polymer
material of the liner to facilitate the passage of the injection
nozzle into the container.
[0065] In various embodiments, the thickness of central liner
portion 160 is between 0.015 inches and 0.060 inches, and more
specifically is between 0.015 inches and 0.050 inches. In one
specific embodiment, the thickness of central liner portion 160 is
0.020 inches plus or minus 0.003 inches. In another specific
embodiment, the thickness of central liner portion 160 is 0.030
inches plus or minus 0.003 inches. In another specific embodiment,
the thickness of central liner portion 160 is 0.040 inches plus or
minus 0.003 inches. In another specific embodiment, the thickness
of central liner portion 160 is 0.050 inches plus or minus 0.003
inches. In one embodiment, the thickness of central liner portion
160 is more than twice the thickness of the outer liner portion and
more than twice the thickness of top wall 152. In various
embodiments, the thickness of central liner portion 160 is between
0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050
inches, and more specifically is between 0.010 inches and 0.030
inches. In various embodiments, the central liner portion 160 is
between 0.020 inches and 0.110 inches, specifically 0.020 inches
and 0.100 inches, and more specifically is between 0.020 inches and
0.080 inches.
[0066] Referring to FIG. 8, a closure 170 is shown. Closure 170
includes a top panel 172, a skirt 174 extending downward away from
top panel 172, and a liner 176. Closure 170 includes a recess 178
formed in top panel 172 that is recessed below the upper most edge
of shoulder 180. Closure 170 also includes a peripheral sealing rib
182. Similar to the embodiments discussed above, liner 176 acts as
a self-sealing structure to reseal closure 170 following the
withdrawal of the injection nozzle.
[0067] In various embodiments, the thickness of at least the center
portion of liner 176 is between 0.015 inches and 0.060 inches, and
more specifically is between 0.015 inches and 0.050 inches. In one
specific embodiment, the thickness of liner portion 176 is 0.020
inches plus or minus 0.003 inches. In another specific embodiment,
the thickness of liner 176 is 0.030 inches plus or minus 0.003
inches. In another specific embodiment, the thickness of liner 176
is 0.040 inches plus or minus 0.003 inches. In various embodiments,
the thickness of central liner portion 176 is between 0.010 inches
and 0.110 inches, specifically 0.010 inches and 0.050 inches, and
more specifically is between 0.010 inches and 0.030 inches. In
various embodiments, the central liner portion 176 is between 0.020
inches and 0.110 inches, specifically 0.020 inches and 0.100
inches, and more specifically is between 0.020 inches and 0.080
inches.
[0068] Referring to FIG. 9, a closure 190 is shown. Closure 190
includes a top panel 192, a skirt 194 extending downward away from
top panel 192, and a liner 196. Closure 190 includes a recess 198
formed in top panel 192 that is recessed below the upper most edge
of shoulder 200. Closure 190 also includes a peripheral sealing rib
202. Similar to the embodiments discussed above, liner 196 acts as
a self-sealing structure to reseal closure 190 following the
withdrawal of the injection nozzle.
[0069] Similar to closure 160 shown in FIG. 7, top panel 192
includes a central bore 204. Liner 196 includes a central portion
206 that extends through the central bore 204 such that the outer
surface of central liner portion 206 is substantially coplanar with
the outer surface of top panel 192. This embodiment provides a
central window or passage filled with the compliant polymer
material of the liner to facilitate the passage of the injection
nozzle into the container.
[0070] In various embodiments, the thickness of central liner
portion 206 is between 0.015 inches and 0.060 inches, and more
specifically is between 0.015 inches and 0.050 inches. In one
specific embodiment, the thickness of central liner portion 206 is
0.020 inches plus or minus 0.003 inches. In another specific
embodiment, the thickness of central liner portion 206 is 0.030
inches plus or minus 0.003 inches. In another specific embodiment,
the thickness of central liner portion 206 is 0.040 inches plus or
minus 0.003 inches. In another specific embodiment, the thickness
of central liner portion 206 is 0.050 inches plus or minus 0.003
inches. In one embodiment, the thickness of central liner portion
206 is more than twice the thickness of the outer liner portion and
more than 1.5 times the thickness of top wall 192. In various
embodiments, the thickness of central liner portion 206 is between
0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050
inches, and more specifically is between 0.010 inches and 0.030
inches. In various embodiments, the central liner portion 206 is
between 0.020 inches and 0.110 inches, specifically 0.020 inches
and 0.100 inches, and more specifically is between 0.020 inches and
0.080 inches.
[0071] As noted above, in some embodiments, injection system 10 may
be configured to inject fluid into a sealed container without
piercing the top wall or the liner of the closure. In some
embodiments, the injection nozzle of system 10 may engage with a
valve structure located in the top wall of the closure. In such
embodiments, the valve structure is a one way valve that permits
fluid to be injected through the valve but prevents fluid from
escaping out of the container. In one embodiment, the valve in the
closure is configured to only open a single time, and, in this
embodiment, the valve will permanently seal closed following
injection of the pressurizing fluid through the valve and into the
container.
[0072] Referring to FIG. 10, closure 210 includes a top panel 212,
a skirt 214 extending downward away from top panel 212 and a liner
216. Closure 210 is substantially the same as closure 80, shown in
FIG. 3, except that closure 210 includes a valve, shown as flap
valve 220, coupled to a through bore 222 formed in top panel 212.
Valve 220 includes flaps 224 that are biased to the closed position
shown FIG. 10. Upon application of sufficient pressure to the outer
surface of valve 220 by the fluid injection nozzle of system 10,
flaps 224 open allowing the injected fluid to flow into the
container. Once filling is completed and the pressure supplied by
the injection nozzle is removed, flaps 224 snap back to the closed
position shown in FIG. 10 hermetically sealing closure 210.
[0073] Referring to FIG. 11, closure 230 includes a top panel 232,
a skirt 234 extending downward away from top panel 232 and a liner
236. Closure 230 is substantially the same as closure 80, shown in
FIG. 3, except that closure 230 includes a valve, shown as ball
check valve 240, coupled to a through bore 242 formed in top panel
232. Valve 240 includes an outer collar 244 and a ball 246. Outer
collar 244 couples to the inner edge of bore 242, and collar 244
includes a central channel 248. Ball 246 is located within central
channel 248 and is moveable between opened and closed positions.
Ball 246 is biased to the closed position shown FIG. 11. Upon
application of sufficient pressure to the outer surface of valve
240 by the fluid injection nozzle of system 10, ball 246 moves
downward to the open position allowing the injected fluid to flow
into the container. Once filling is completed and the pressure
supplied by the injection nozzle is removed, ball 246 snaps back to
the closed position shown in FIG. 11, hermetically sealing closure
230.
[0074] Referring to FIG. 12, a closure 260 is shown. Closure 260 is
substantially similar to closure 170 shown in FIG. 8 except closure
260 includes no liner and includes flap valve 220 coupled to a bore
through the top panel of closure 260. Referring to FIG. 13, closure
270 is shown. Closure 270 is substantially similar to closure 170
shown in FIG. 8 except closure 270 includes no liner and includes
ball check valve 240 coupled to a bore through the top panel of
closure 260.
[0075] For the purposes of this discussion, the term coupled means
the joining of two components directly or indirectly to one
another. Such joining may be stationary in nature or movable in
nature. Such joining may be achieved with the two members and any
additional intermediate members being integrally formed as a single
unitary body with one another or with the two members or the two
members and any additional member being attached to one another.
Such joining may be permanent in nature or alternatively may be
removable or releasable in nature.
[0076] In various embodiments, the containers discussed herein are
any hermetically sealed or sealable containers. In various
embodiments, the containers discussed herein are containers
configured to hold consumable or edible products (e.g. a beverage,
water, food, medicine, etc.). In the embodiment shown in FIG. 1,
the container is a molded (e.g., blow-molded) thermoplastic
beverage container configured to hermetically hold a beverage
(e.g., soda, water, juice, fortified or nutrient water, tea, sports
drink, energy drink, milk, milk-based beverages, etc.). In
addition, the closures discussed herein are closures suitable for
maintaining a hermetic seal. In particular embodiments, the
closures discussed herein are injection molded thermoplastic
closures.
[0077] It should be understood that the figures illustrate the
exemplary embodiments in detail, and it should be understood that
the present application is not limited to the details or
methodology set forth in the description or illustrated in the
figures. It should also be understood that the terminology is for
the purpose of description only and should not be regarded as
limiting.
[0078] Further modifications and alternative embodiments of various
aspects of the invention will be apparent to those skilled in the
art in view of this description. Accordingly, this description is
to be construed as illustrative only. The construction and
arrangements, shown in the various exemplary embodiments, are
illustrative only. Although only a few embodiments have been
described in detail in this disclosure, many modifications are
possible (e.g., variations in sizes, dimensions, structures, shapes
and proportions of the various elements, values of parameters,
mounting arrangements, use of materials, colors, orientations,
etc.) without materially departing from the novel teachings and
advantages of the subject matter described herein. Some elements
shown as integrally formed may be constructed of multiple parts or
elements, the position of elements may be reversed or otherwise
varied, and the nature or number of discrete elements or positions
may be altered or varied. Other substitutions, modifications,
changes and omissions may also be made in the design, operating
conditions and arrangement of the various exemplary embodiments
without departing from the scope of the present invention.
[0079] While the current application recites particular
combinations of features in the claims appended hereto, various
embodiments of the invention relate to any combination of any of
the features described herein whether or not such combination is
currently claimed, and any such combination of features may be
claimed in this or future applications. Any of the features,
elements, or components of any of the exemplary embodiments
discussed above may be used alone or in combination with any of the
features, elements, or components of any of the other embodiments
discussed above.
* * * * *