The present invention relates to composite barrels for storing liquids such as wine, spirits and the like.
Wine barrels and in particular oak wine barrels have been used as receptacles for storing and ageing wine during the wine making process. When wine is stored in a wooden barrel, particularly oak, a tannin flavor is imparted by wood phenolics to the wine. This enrichment generally improves the quality of the wine. It is therefore generally considered desirable to age wine in an oak receptacle to impart sought-after characteristics into the wine.
However, oak barrels are increasingly expensive to purchase and maintain. Their high cost is at least partly due to the fact that their construction can require staves that are generally made from boards taken from the most valuable parts of the oak trees as well as skilled coopers required to make and repair the barrels. Construction of a typical 59 gallon wine barrel requires the consumption of two full oak trees, each one at least approximately one hundred years old.
With continuous use of wooden wine barrels over extended periods, the inner surfaces of the barrel becomes contaminated with wine residue and the much sought-after wood flavor becomes less and less available. As a result, oak wines barrels impart varying sensory characteristics to the wine according to the age of the barrel, making reproducibility from batch to batch difficult.
Further, oak wine barrels when not in use are subject to attack by certain types of bacteria or fingi and frequently must be treated with suitable chemicals to avoid any serious contamination. Accordingly, it is sometimes necessary to discard not only used barrels, but contaminated wooden wine barrels as well, since chemical treatments are sometimes ineffective and can alter the taste of the wine.
Certain exemplary embodiments can provide a composite barrel for storing a liquid, the composite barrel comprising: a polymer body having an open end; a wooden head attachable to the open end of the polymer body the wooden head having an interior surface configured to increase surface area for contact with the liquid and an exterior surface; and a sealing mechanism for sealingly securing the wooden head to the polymer body.
Certain exemplary embodiments can provide a wooden head for use with a composite barrel for storing a liquid, the wooden head comprising an interior surface contactable with the liquid and an exterior surface; and a plurality of channels formed on the interior surface to increase surface area for contact with the liquid.
The polymer body 100 may be made of food grade plastic or other plastics suitable for contact with liquid for consumption including polymers and copolymers. The polymer body 100 may be made of rotomolded plastic, a plastic casting or by other methods. The polymer body 100 may comprise additional structural members or elements such as longitudinal or lateral ridges, bulges or other strengthening members for imparting strength to the barrel. The polymer body 100 may also include other aesthetic features or shapes as desired and may be made to resemble the shape or appearance of a typical wine barrel.
The wooden head 120 has an interior surface for contact with the contents of the barrel, for example wine. The wooden head 120 can impart various characteristics to the contents of the barrel depending on the type of wood and other factors. The wooden head 120 can, for example, impart tannin to the contents of the barrel. The interior surface is configured to increase the surface area in potential contact with the contents of the barrel thereby bringing more wood into contact with the contents of the barrel. In this way, more characteristics of the wood of the wooden bead 120, such as tannin, may be imparted into the contents of the barrel as compared to a non-configured wooden head.
This may be controlled or manipulated based on, for example, the type of wood (e.g., oak and cherry), the age of the wood, the thickness the wood, the size of the surface area of wood in contact with the contents of the barrel, etc. Moreover, the configuration of the interior of the wooden head 120 may be selected based on the desired amount of contact one wishes to have between the contents of the barrel and the wooden head 120. In addition, oxygenation of the contents of the barrel may take place through the wooden head 120 and may also be controlled based on, for example, the type of wood, the age of the wood, the thickness the wood, the size of the surface area of wood in contact with the contents of the barrel, etc.
The outer ring 110 fits within a flange on the end of the polymer body 100 and is adapted to seat the wooden head 120.
The inner ring 150 nests within and releasably locks to the outer ring 110 and secures the wooden head 120 to the polymer body 100, as will be shown in more detail below with reference to
Although an outer ring 110 and an inner ring 150 are illustrated having an attaching mechanism for securing the wooden head 120 to the polymer body 100, other attaching mechanisms may be utilized provided that sealed attachment of the wooden head 120 to the polymer body 100 is achievable. Other types of attachment mechanisms can include a friction fit, an interference fit, threaded attachment of the wooden head 120 to the polymer body 100, adhesive attachment, a welded attachment, etc.
By utilizing a polymer body 100 in construction of the barrel in place of oak staves it is unnecessary to cultivate trees for use in the manufacture of the staves and the services of a cooper are not required. This can result in a cost savings over a standard oak wine barrel. Furthermore, the wooden head 120 may be made from discarded or previously used wood that can be recycled or reconditioned for use in the composite barrel. The wooden head 120 may be made from a series of planks expandable when soaked to thereby strengthen the seal between the polymer body 100, the inner ring 150 and the outer ring 110. The planks may be quarter sawn for more predictable expansion and contraction. As a result of using smaller planks joined to form the wooden head 120, wood may be used having a smaller cross-section or diameter thereby allowing for smaller trees to be cultivated and further reducing costs of the manufacture of the barrel and the wooden head 120. Manufacturing cost can be further reduced by utilizing recycled or reconditioned wood.
The interior surface of the wooden head 120 for contact with the contents of the barrel is configured to increase the surface area relative to a flat surface or non-configured surface. By increasing the surface area of wood for contact with the contents of the barrel, more characteristics of the wood may be imparted to the contents of the barrel. In practice, a completely wooden barrel may be simulated as desired. Alternatively, various patterns of configured interior surface may be used to increase the surface area of the wooden head from about 1% to over 100%. Various patterns of configured interior surface may be chosen depending on the desired characteristics of the contents of the barrel.
If a reproducible pattern is used to increase the surface area of the interior surface of the wooden head 120, the wooden head may be replaced with a replacement wooden head having an identical surface area thereby allowing for the same characteristics to be imparted to the contents of the barrel. This allows for improved reproducibility between batches of wine even when the wooden head 120 is replaced. When viewed in combination with the lower replacement cost of the heads, this means that the wooden head 120 may be replaced more often with one of substantially identical interior surface area allowing for reproducible wine or other spirits or contents at a lower cost.
The polymer body 100 may further include a bung hole 170 for receiving a bung. This allows for, among others, monitoring of the contents of the barrel as well as the status of the interior of the barrel including the interior surface of the wooden head 120. Once it has been determined that the interior surface of the wooden head 120 is occluded, dirty, depleted, broken down, or requires replacement, a replacement wooden head may be installed on the polymer body 100, optionally having an identically configured pattern on the interior surface.
The outer ring 110 may be positioned during manufacture of the polymer body 100, for example during rotomolding of the polymer body 100 such that on completion of the rotomold, the outer ring 110 is situated in place and secured by the connectors 140. The internal edge of the connectors 140 is substantially flush with the interior surface of the outer ring 110 allowing for passage of the wooden head 120. Each connector 140 has an internal bore for receiving a fastener, such as a pin, a screw or the like. The outer ring 110 may have an internal annular lip 115 for seating the wooden head 120. Alternatively, if the outer ring 110 does not have an internal annular lip 115, the polymer body 100 may have an annular lip upon which the wooden head is seated. Alternatively, the outer ring 110 and the polymer body 100 may both have a lip upon which the wooden head 120 is seated as will be shown with reference to
The wooden head 120 may further comprise an annular seal 130 that may be seated in an annular groove 250 in the wooden head 120. The annular seal 130 presses against the interior surface of the outer ring 110 sealing the wooden head 120 and the outer ring 110 from egress of the contents of the barrel. The annular seal 130 may be selected from, for example, an O-ring or a gasket.
The inner ring 150 may comprise a slanted slot 160 for communication with the connector 140 of the outer ring 110. The slanted slot 160 is slanted such that after insertion of a fastener 300 through the slanted slot 160 and into the internal bore of the connector 140, rotation of the inner ring 150 in one direction shifts the inner ring 150 towards the wooden head 120 thereby imparting a sealing force against the wooden head 120 further strengthening the seal between the polymer body 100, the outer ring 110 and the wooden head 120. The slanted slot 160 may have sections along its perimeter that are scalloped or serrated to aid in gripping the fastener 300 inserted therethrough. The slanted slot 160 may alternatively be completely free of scalloped or serrated sections or may be fully scalloped or serrated.
To distribute the force imparted by the inner ring 150 against the wooden head 120, the inner ring 150 further comprises an annular interior lip 165 adapted to press against the wooden head 120 when the inner ring 150 is nested in the outer ring 110.
To aid in rotating the inner ring 150, the inner ring 150 may comprise one or more notches 155 for interface with a tool, either manually operated or automated, for rotating the inner ring 150.
The annular flange 270 also comprises an optional annular lip 105 for further reinforcing, securing and/or supporting the outer ring 110 and the wooden head 120. Once the wooden head 120 is seated on the outer ring 110, an inner ring 150 is nested in the outer ring 110 and may be secured in place using a fastener 300 in connection with the connector 140 which has an internal bore for receiving the fastener 300. If the inner ring 150 comprises slanted slots 160 (as shown in
Wetting the wooden head 120 after seating in the outer ring 110 may be done to expand the wooden head 120 and increase the strength of the seal between the wooden head 120 and the polymer body 100. In order to facilitate this technique, the planks 200 of the wooden head 120 may be quarter sawn so that the expansion of the planks is more predictable.
Although a typical flange 270 and annular lip 105 are illustrated in
The fasteners 300 of the embodiment illustrated in
Furthermore, the exterior surface of the wooden head 120 may also be configured to increase the surface area so that simply turning over the wooden head 120 exposes a fresh or unblemished surface for contact with the contents of the barrel.
Although the
Various embodiments provide for a composite barrel comprising a polymer body and at least one replaceable wooden head. The replaceable wooden head has an interior surface for contact with the contents of the barrel that is configured to increase the surface area and thereby increase the amount of wood characteristics, such as tannin, which may be imparted into the wine. Oxygenation of the contents of the barrel may occur through the wooden head. The replaceable wooden head consumes less wood than a typical oak barrel thereby lowering replacement costs. The interior surface of the replaceable wooden heads may be monitored throughout the storage of the contents of the barrel to watch for occlusion, break down of the wood and the like. The surface area of the interior surface of the wooden head may be reproducible allowing for a consistent amount of wood contact with the stored contents and consistent oxygenation between replacement of the wooden heads. The composite or polymer nature of the composite barrel body further minimizes absorption of spilt wine and bacteria growth and/or insect contamination as a result.
In one variation of the composite barrel, a stainless steel sleeve is inserted into the polymer body 100 of the barrel for contact with the contents of the barrel. The stainless steel sleeve may either completely or partially cover the interior surface of the polymer body 100.
It is apparent to one skilled in the art that numerous modifications and departures from the specific embodiments described herein may be made without departing from the spirit and scope of the invention.
Number | Date | Country | Kind |
---|---|---|---|
11405837 | Apr 2006 | US | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/CA07/00631 | 4/17/2007 | WO | 00 | 4/8/2009 |