Patent Application
20210031973
Embodiments of the present invention generally relate to domed metal containers, and more specifically to pressurized metallic food containers with liquid nitrogen wells and various closure mechanisms.
Containers, and more specifically food containers, are generally plastic, cardboard, or metal. The plastic containers are difficult to recycle and, thus, lead to a lot of landfill waste. Cardboard containers can be weak and breakable food, e.g., chips or crisps, can be crushed or damaged in weak cardboard containers. Alternatively, cardboard containers are made with thick sidewalls and/or may have a foil lining and metal bottom portion. The thick cardboard and foil attached thereto can be difficult to recycle and can lead to a lot of landfill waste. Containers with thick cardboard and foil sides interconnected to a metal bottom are expensive and time consuming to manufacture because they involve many steps and different materials. These cardboard and metal containers and are also susceptible to water damage and failure. For example, food containers should be impermeable to prevent spoilage due to moisture and other contaminants. Cardboard is not impermeable and, thus, a metal lining must be used. However, if the metal lining is not properly sealed to a metal bottom and a metal or plastic lid, then leakage can occur, permitting moisture and other contaminants into the container.
Often times chips are sold in bags, but the chips can be crushed or damaged in bags. Additionally, the bags are over pressurized and underfilled in order to protect the chips from breaking. Additionally, bags are difficult to recycle and lead to landfill waste. Stackable chips are often sold in cylindrical containers that suffer from many of the disadvantages described above, in addition to flat bottoms that create pressure points for curved chips and increase chip breakage. Further, bags and soft cylindrical containers can make shipping more difficult if the contents are fragile, such as is the case with chips. Thus, there is an unmet need to provide a rigid, cost-effective metal container that can be used to store frangible foodstuffs and dry food with reduced food breakage that is also recyclable and, therefore, environmentally sustainable.
These and other needs are addressed by the various embodiments and configurations of embodiments of the present invention. This invention relates to a novel thin-walled metallic food container and methods for providing a metallic food container with a unique domed-shaped bottom portion, a nitrogen well proximate the domed-shaped bottom, various closure mechanisms, and pressurizing the container after dry food has been placed in the thin-walled metal container. In one embodiment, the lower dome portion of the container has a hyperbolic paraboloid shape, which is characterized by two distinct arcs or radii of curvature oriented at substantially right angles with respect to each other and in opposite directions, i.e., one curves upwardly and the other curves downwardly. In another embodiment, the lower dome portion has a symmetrical shape with only one radius of curvature. The novel container is easily recyclable, can hold a large number of stackable chips or other food product, has a thin contour wall, has various closure mechanisms, and is sturdy such that the chips will not break in transit or after the consumer purchases the container of food. Note that the terms “chips” and “crisps” are used interchangeably herein.
Metal containers can be used for food storage, but without internal pressurization thick walls must be used. Thin-walled metal food containers need increased internal pressure to maintain strength and prevent food breakage, but pressurizing the container after the food, especially dry food products, has been put into the container can be problematic. Accordingly, a novel method is provided herein for pressurizing a container after the container has been filled with dry food. In some embodiments, liquid nitrogen is introduced into the container after the container has been filled with dry food and then the container is sealed such that the liquid nitrogen turns to gas and pressurizes the container.
Features of the present invention may be employed in a wide range of food containers, including pressurized food containers with tear away lids or reusable lids. Although the invention generally relates to metallic food containers, the invention and features described herein could easily be implemented on a variety of plastic containers, for example plastic sandwich containers commonly found in convenient stores.
Embodiments of the present invention differ from prior food containers because prior containers for holding stackable chips do not have any antibreakage features, nitrogen wells, or utilize pressurized metal containers. Prior art containers consist of flat metal ends seamed directly to cardboard and foil container side walls.
Thus, it is one aspect of various embodiments of the present invention to provide a metallic food container that reduces the point load on the stackable saddle chips and decreases the amount of chip breakage that occurs. In some embodiments, the metallic food container has a bottom portion shaped similarly to the stackable chips such that the domed bottom portion of the container can cradle and contact the chip in multiple locations. In various embodiments, the metallic food container has a unique, domed bottom portion with a first radius of curvature (R1) along a first centerline of the bottom, for example along the major axis of the chip and from chip low point to low point, and a second radius of curvature (R2) along a second centerline of the bottom, for example along the minor axis of the chip and from chip high point to high point (depending on the orientation of the chip, i.e., whether the radius of curvature along the major axis is curving upward or downward). In some embodiments, the first centerline of the bottom is substantially perpendicular to the second centerline of the bottom. One advantage of some embodiments is that the curve of the domed bottom portion aligns with and fits the hyperbolic-paraboloid-shaped or ellipsoid-shaped stackable crisps.
In some embodiments, the dome on the bottom portion of the container is symmetrical, meaning there is a consistent radius of curvature defining the entire dome. Thus, in some embodiments the domed portion has an ellipsoidal shape. For example, in some embodiments the domed portion has a spherical shape, in other embodiments the domed portion has a spheroidal shape, and in still other embodiments the domed portion has a tri-axial ellipsoidal shape. If the container holds spheroid-shaped, tri-axial-ellipsoid-shaped, or hyperbolic-paraboloid-shaped crisps and the bottom has a spherical-shaped dome, then the radius of curvature of the dome will match one radius of curvature of the crisp, e.g., the major or minor axis radius of curvature. If the container holds spheroid-shaped, tri-axial-ellipsoid-shaped, or hyperbolic-paraboloid-shaped crisps and the bottom has a spheroid-shaped or a tri-axial-ellipsoid-shaped dome, then the dome will have two radii of curvature that match the two radii of curvature of the crisps.
Having a dome-shaped bottom portion, rather than a flat bottom, requires that the container filler position the chips in the proper orientation regarding right side up or upside down to reduce crisp breakage because the correct chip curve should be placed on the matching container bottom curve. Further, if the dome-shaped bottom portion has a symmetrical shape with only one radius of curvature, then the filler can position the crisps in any direction relative to the 360° of rotation of the crisps as long as the correct side of the crisps is facing downward. For example, if the crisps are oval shaped, the minor or major axis could be in any direction (360°) if the container is circular and the domed bottom portion is symmetrical as long as the proper crisp curve is facing downward. However, this embodiment could lead to problems because the filler will not know exactly where the crisps are positioned relative to the dome and will not know the preferred location to inject the liquid nitrogen such that the liquid nitrogen avoids contacting the crisps. This is only a problem if the container has liquid nitrogen injected after the crisps are in the container and prior to closure, the container is circular shaped, and the crisps are not circular (e.g., the crisps are oval shaped). As the filling process is likely automated, some containers may have the crisps oriented in one direction while other containers have the crisps oriented in another direction (i.e., rotated around a longitudinal axis of the container), which means that the liquid nitrogen could be injected at different locations relative to the crisps. Having a domed bottom portion with two different radii of curvature is advantageous because during filling the filler should position the chips in the proper direction relative to the curves of the domed bottom for the chips to sit on the dome properly. When this happens, and in this embodiment, the filler will know how the crisps are oriented relative to the container and know where the preferred liquid nitrogen injection location is, meaning the liquid nitrogen can be injected at the preferred location every time.
In one aspect of the present invention, the container may have indicia or other forms of marking on the exterior surface, which identifies the orientation of the container and internal geometry. It is another aspect of the present invention that the container can be properly oriented prior to filling to assure that the crisp or other food product is positioned in the proper orientation within the container. Accordingly, the indicia or other marking can be used by the system or machinery to properly align the container relative to the food product put into the container and properly align the container for injection of the liquid nitrogen. For example, the following patents and patent applications relate to orienting the container and are incorporated by reference herein: U.S. Pat. No. 9,259,913 to Ellefson; U.S. Pat. No. 9,340,368 to Ellefson et al.; U.S. Pat. No. 6,524,048 to Tsukada et al.; U.S. Pat. No. 4,016,968 to Stelter; and U.S. Patent Publication No. 2017/0197241 to Ellefson.
It is one aspect of the present invention to provide a food container that is made of an impermeable metal material. In various embodiments, the metallic food container has thick metal walls that do not require internal pressurization to gain strength. For example, the metal walls may be at least about 0.005″ to about 0.010″ thick such that internal pressurization is not required for strength. In one embodiment, the metal walls are at least about 0.006″ thick such that internal pressurization is not required for strength. In alternative embodiments, the metallic food container has thin metal walls that require internal pressurization for strength. In some embodiments, the walls are between about 0.003″ and 0.005″ thick. In a preferred embodiment of the thin-walled container, the walls are about 0.004″ thick. In some embodiments, the walls of the thin-walled container have a maximum thickness of about 0.005″.
In some embodiments, the metallic food container has an aluminum wall (which can be thin) and an integral bottom portion without any seam connecting this bottom portion to a lower end of the aluminum sidewall. Alternately, the bottom portion may be a separate piece that is seamed to the lower end of the sidewall by double seaming or other methods well known by those skilled in the art. Further, in one embodiment the lightweight container has thin sidewalls and is pressurized to gain strength. To prevent the thin aluminum walls from being damaged, which could cause the chips or other food products to break, the internal pressure of the container must be higher than the atmospheric pressure. In some embodiments, this is achieved by using a container with a nitrogen well proximate the domed bottom portion. Liquid nitrogen (which is in liquid form due to being stored and dispensed at a high pressure and/or low temperature) is inserted into the nitrogen well and then the container is sealed. The liquid nitrogen changes into a gas because the container is at a lower pressure and/or higher temperature than the stored liquid nitrogen, thus the nitrogen decreases in pressure and/or increases in temperature and the gaseous nitrogen pressurizes the container. In order for liquid nitrogen dosing to effectively pressurize a container, some of the liquid nitrogen must remain in the liquid state at least until the package is sealed. After the container is sealed, any additional liquid nitrogen converted to gas will cause an increase in package pressure and improve rigidity. If the nitrogen evaporates before the container can be sealed, then there is little to no increase in the internal package pressure, which can result in paneling or pulling a vacuum and container damage during shipping.
Additionally, embodiments of the present invention include food containers with standard internal coatings or chemical treatments. For example, epoxy coatings or BPANI coatings can be used. Alternatively, the container could be uncoated but chemically treated to resist discoloration. For example, the container could have a chemical treatment such as zirconium or anodizing.
In some embodiments, the container has a flat bottom and an insert with the preferred dome shape and/or nitrogen well is inserted into the bottom of the container before the container is filled with crisps or other food items. The insert could have one radius of curvature, such as a typical symmetrical dome shape. Alternatively, the insert could have a specific hyperbolic paraboloid shaped to match the crisps in the container or other shaped food stuff. The insert can be a plastic material, a metallic material, a composite material, cardboard, or other material.
Another advantage of pressurizing the container is that contamination and/or spoilage is easily detected and recognized. Thus, if the container is opened or punctured, then the internal nitrogen and other gas escapes from the container and the container is depressurized (i.e., the internal pressure of the container will be equal to the atmospheric pressure). Once the container is depressurized, the thin aluminum walls will be weaker and the container will feel “soft.” A consumer or retailer will be able to feel the difference between a pressurized (firm) container and depressurized (soft) container, which will signal to the consumer whether the container has been opened, punctured, or otherwise tampered. Moreover, the pressurized container creates an audible cue when the container is opened. Consumers like the audible cue because then they know the package has not been tampered with and they know the food is fresh or not contaminated. In some embodiments, Valcorin (i.e., dimethyl decarbonate) is added to the container to sterilize the headspace of the container.
It is one aspect of embodiments of the present invention to provide a container that prevents the liquid nitrogen from contacting the chips or other food in the container. When liquid nitrogen contacts the crisps or other food, the nitrogen is absorbed and the surface area of the nitrogen dramatically increases, resulting in almost immediate vaporization. Then the nitrogen gas escapes before the container can be closed or sealed and the lightweight container will not have sufficient pressure to gain strength. In prior art stacking chip containers, the bottom of the container was flat. If nitrogen dosing was desired in a container with a flat bottom, then nitrogen dosing onto a flat surface would result in contact between the crisps and liquid nitrogen, which causes the nitrogen to flash-off and quickly evaporate out of the container before a lid, cap, or other end closure can be put onto the container.
The nitrogen well is a feature that does not allow the chips to enter the area where the liquid nitrogen resides due to simple geometry incompatibilities. Additionally, the nitrogen well is the lowest point of the container such that the liquid nitrogen will fall down into and reside in the nitrogen well due to gravity. Therefore, the chips will not touch the liquid nitrogen once the liquid nitrogen is in the well.
The novel nitrogen well shape has additional advantages, including preventing the liquid nitrogen from contacting the chips, which allows the container to be nitrogen dosed either before or after the chips are placed in the container and before application of the end closure or lid. The novel nitrogen well keeps the liquid nitrogen separate from the chips. In some embodiments, the well has an area for the nitrogen that is positioned below and away from the chips, which prevents contact with the chips or other foodstuff. Starting at the container sidewall and moving down the container toward the bottom, there may be a series of reduced radii that are recessed from the subsequent dome. This series of radii make up the nitrogen well. The nitrogen well is shaped and positioned such that chips or other food stuff are unable to fall into the recessed well area. The container's near-vertical sidewall terminates in a sharp radius, which leads to a larger radius that matches the radius of the chips placed in the container. Moreover, a nitrogen well with a small radius of curvature, and thus small width, at the bottom prevents the nitrogen from spreading out and evaporating quickly due to an increase in surface area. In some embodiments, the end closure or lid of the container has a nitrogen well into which liquid nitrogen can be injected to increase the internal pressure of the container once the container is sealed.
It is another aspect of various embodiments of the present invention to provide a metallic food container that is easily recyclable. Accordingly, in some embodiments, the container is comprised of a recyclable metal material.
In another aspect of the present invention, a metallic food container is provided that is manufactured with conventional manufacturing equipment. It is one aspect of embodiments of the present invention to provide a metallic food container with a domed bottom portion that is formed using traditional draw and iron techniques. In some embodiments the domed bottom portion also includes a nitrogen well surrounding the domed portion. More specifically, a method for forming a metallic food container is provided, wherein the typical draw and iron steps are used to form a blank (i.e., a circular shaped flat piece of metal) into the container body (i.e., sidewalls and bottom portion). A punch can be used to shape the bottom portion into the final desired dome shape and/or nitrogen well.
Another aspect of embodiments of the present invention is to provide a method for filling a food container with food and pressurizing the food container to a predetermined rigidity. In some embodiments this method includes the following steps: a) providing a metallic food container with a domed bottom portion and a nitrogen well surrounding the domed portion positioned below the domed portion; b) filling the container with stackable chips or other food; c) injecting a predetermined amount of liquid nitrogen into the nitrogen well; and d) sealing the container using a lid or end closure. Steps (b) and (c) can be switched, i.e., in the reverse order, in some embodiments.
It is preferred to fill the container with the crisps before injecting the nitrogen because filling the container with crisps after the nitrogen must be done quickly such that the nitrogen does not evaporate prior to closure and the crisps must be oriented in the correct position. In some embodiments, the container must be sealed within about 15 seconds after the nitrogen is injected into the container. In various embodiments, the container must be sealed within about 5 seconds after the nitrogen is injected into the container. In one embodiment, the container is sealed within 1 second of receiving the liquid nitrogen. If the liquid nitrogen is injected into the container after the container is filled with chips or other food, then the only food that can be put into the container is stackable food or food that permit a line of sight to the bottom of the container, i.e., a line of sight to the nitrogen well. Thus, loose foods like peanuts cannot be put into the container and then liquid nitrogen injected in the container because the liquid nitrogen would contact the peanuts and evaporate. If the liquid nitrogen is injected into the container before the container is filled with food, then a line of sight to the well is not necessary after the food is in the container and foods like peanuts can be put into the container. Additionally, loose foods like peanuts do not need to be oriented in a specific direction, unlike stackable chips, and the container could be filled more quickly with loose foods, thus permitting the liquid nitrogen to be injected prior to the container being filled with food and the container sealed before the liquid nitrogen vaporizes and evaporates. The amount of liquid nitrogen injected depends on how much liquid nitrogen is needed in the container when the container is sealed and how long between the time the nitrogen is injected into the container to when the container is sealed.
Additionally, it is preferred that there is no water, and minimal water vapor, in the container when the liquid nitrogen is injected. In some embodiments, the liquid nitrogen is injected into the container using a targeted spray directed away from the food and into the nitrogen well. Preferably, the liquid nitrogen is sprayed into the portion of the well between the minor axis of an oval chip and the sidewall because there is more space between the chip and the sidewall here, which reduces the chances and/or amount of nitrogen contacting the chips. In various embodiments, the liquid nitrogen is injected down into the well directly using a long needle-shaped tube. In other embodiments, the liquid nitrogen is sprayed onto the container sidewall and drips down the sidewall into the nitrogen well. In alternative embodiments, the liquid nitrogen may be dosed on top of the chip stack or other food in the container and as long as some of the liquid nitrogen waterfalls down off of the chip stack and into the nitrogen well, which occurs due to gravity, then the container can be sealed and have an increased internal pressure. Although, it is preferred that the liquid nitrogen not contact the food. However, if contact occurs, then most of the liquid nitrogen will “dance” off of the food, like water in a skillet. Therefore, most of the liquid nitrogen does not soak into the food it contacts. Additionally, contact of the liquid nitrogen with the food is unlikely to affect the taste of the food.
Some embodiments may include a straw-like portion extending from the container sidewall and extending the entire length or a portion of the length of the sidewall and into the well such that the liquid nitrogen is directed into the straw-like portion and down into the well without contacting the food. The straw-like portion directs the liquid nitrogen into the well. Alternatively, a removable straw can be placed in the container before it is filled with food, for example if loose foods like peanuts are packaged, then the container can be filled with food and the nitrogen doser can shoot the nitrogen into the container via the removable straw. Finally, the removable straw can be removed before the container is sealed or it can remain in the container and removed by the consumer when he/she opens the container.
If the chips are placed into the container before the liquid nitrogen, then care must be taken to ensure that crumbs to not end up in the nitrogen well because the liquid nitrogen will contact the crumbs and can immediately flash off or evaporate before the container can be sealed, which results in a minimal increase in internal package pressure. In alternative embodiments, the liquid nitrogen is injected into the nitrogen well before the container is filled with stackable chips or other food. The nitrogen well can be filled using standard equipment and then the container is filled with chips and sealed. For example, standard liquid nitrogen dosing equipment can be purchased from Vacuum Barrier Corporation or Chart.
The amount of liquid nitrogen needed to properly pressurize the container varies depending on how and when the liquid nitrogen is injected, the amount of increased pressure desired in the container, and the size of the container. The goal is for the sealed container to have a positive pressure relative to the ambient external air. It is preferred that the container have a pressure of at least about 10 psi (at about 70° F.) higher than the ambient external atmosphere at the location where the container is filled and sealed. The container can have a pressure greater than 10 psi above ambient pressure at 70° F., but 10 psi above ambient pressure is the minimum required for consistency of the containers and the minimum needed to provide strength for the thin-walled container. Additionally, the larger the container, the more liquid nitrogen required based on the ideal gas law. Additionally, if the liquid nitrogen contacts the crisps, then more liquid nitrogen will be required since some nitrogen will evaporate upon contact. Further, the longer the container is open, i.e., if the container is nitrogen dosed first and then filled with food, the more liquid nitrogen is required.
For example, if a container has 250 mL of gas space in the container, the container has 1 atmosphere (14.7 psia=0 psig) of gas prior to adding any liquid nitrogen, and it is desired that the container have 2 atmospheres (29.4 psia=14.7 psig) of gas after sealing, then 0.313 grams of liquid nitrogen should be added to the container and the container should be sealed almost immediately thereafter.
The exact amount of nitrogen put into the container may not be known. Rather, the variables controlled are the length of time the valve connected to the nitrogen doser is open and the size of the nozzle used for the nitrogen dosing. The nozzle size can vary depending on the amount of liquid nitrogen needed and the speed of the filling system. For example, if the container filling system operates at high speeds, then a larger nozzle will be needed to shoot out the same amount of nitrogen in a shorter amount of time.
In one trial, a 0.105″ nozzle was used to inject liquid nitrogen for 100 milliseconds (i.e., the nozzle was open for 100 milliseconds), which yielded a sealed container with 30% headspace at about 40 psi above atmospheric pressure.
The liquid nitrogen is injected into the container at about 0-5 Kelvin (or about −273° C. to about −268° C.). At this temperature at atmospheric pressure, the nitrogen is in in its liquid phase. However, the cold liquid nitrogen is not stable under atmospheric conditions, i.e., a warmer temperature, and therefore it evaporates rapidly, but not immediately.
In some embodiments, a metallic food container is provided comprising: a cylindrical sidewall with an upper end and a lower end; an opening proximate the upper end; a bottom portion interconnected to the lower end of the cylindrical sidewall, wherein the bottom portion comprises: a dome-shaped portion; and a well positioned proximate to a lower portion of the dome-shaped portion to receive a liquid.
In additional and alternative embodiments, the metallic food container further comprises a neck interconnected to the upper end of the cylindrical sidewall and extending around the upper end of the cylindrical sidewall, wherein the neck extends upwardly from the cylindrical sidewall; a peripheral curl interconnected to an upper end of the neck; a tear away lid secured to a crown of the peripheral curl; threads on an exterior surface of the neck which are adapted to receive a threaded end closure which is selectively removable; and/or an end closure double-seamed to the neck of the container, the end closure having a pull tab for selectively removing at least a portion of the end closure. In additional and alternative embodiments, the bottom portion is integrally interconnected to the lower end of the cylindrical sidewall such that the bottom portion is one piece with the cylindrical sidewall, and/or the well is concentric with the dome-shaped portion.
In some embodiments, a pressurized metallic food container is provided comprising: a cylindrical, substantially vertical sidewall with an upper end and a lower end; a neck interconnected to the upper end of the sidewall and extending upwardly and inwardly from the sidewall; an opening proximate the neck; a bottom portion integrally interconnected to the lower end of the cylindrical sidewall, wherein the bottom portion comprises: a substantially linear outer panel wall extending downwardly from the sidewall; a U-shaped curved wall having a first radius of curvature and interconnected to a bottom portion of the outer panel wall; an inner panel wall extending upwardly from an interior portion of the U-shaped curved wall; a dome-shaped portion with a second radius of curvature, the domed portion interconnected to an uppermost portion of the inner panel wall at a third radius of curvature, wherein the outer panel wall, U-shaped curved wall, and inner panel wall form a well positioned around and concentric with the dome-shaped portion.
In additional and alternative embodiments, the inner panel wall is substantially linear; the first radius of curvature is smaller than the second radius of curvature; the well has a constant height and width around the circumference of the container; and/or the domed portion has a hyperbolic paraboloid shape.
In some embodiments, a pressurized metallic food container is provided comprising: a cylindrical, substantially vertical sidewall with an upper end and a lower end; a neck interconnected to the upper end of the sidewall and extending upwardly and inwardly from the sidewall; an opening proximate the neck; and a bottom portion integrally interconnected to the lower end of the cylindrical sidewall, wherein the bottom portion comprises a dome-shaped portion having a mirror image shape to a food stuff and liquid nitrogen.
In some embodiments, a method of manufacturing a metallic food container is provided comprising: providing a metallic blank in a shape of a circular disc; punching the metallic blank to form a continuous sidewall with an upper end and a lower end and an opening proximate the upper end; shaping a bottom portion interconnected to the lower end of the sidewall, wherein the bottom portion comprises a dome-shaped portion and a well positioned proximate to a lower portion of the dome-shaped portion to receive a liquid, and wherein the domed-shaped portion has a specific profile to match a profile of a food stuff.
In additional and alternative embodiments, the method further comprises applying indicia to an exterior portion of the sidewall, wherein the indicia is provided for proper orientation of the metallic food container. In some embodiments, the method further comprises providing a lid; and securing the lid to the upper end of the continuous sidewall, after the container is filled with food stuff, to form a two-piece metallic food container.
In some embodiments, a method of filling a metallic food container in a pressurized state is provided comprising: providing the metallic food container comprising: a cylindrical sidewall with an upper end and a lower end; an opening proximate the upper end; a bottom portion interconnected to the lower end of the cylindrical sidewall, wherein the bottom portion comprises: a domed-shaped portion with a geometric profile designed to nest with a food stuff; and a well positioned on a lower peripheral portion of the domed-shaped portion to receive a predetermined amount of liquid nitrogen; filling the metallic food container with food; injecting a predetermined amount of liquid nitrogen into the well of the container; sealing the container with an end closure; and pressurizing the container to a pressure above atmospheric pressure, wherein the liquid nitrogen becomes a gas as a result of a decrease in pressure or an increase in temperature.
In additional and alternative embodiments, the pressure above atmospheric pressure is about 10 psi. In various embodiments, the bottom portion is integrally interconnected to the cylindrical sidewall; the dome-shaped portion has a hyperbolic paraboloid shape; and/or the metallic food container further comprises indicia on an exterior portion of the sidewall, and wherein the method further comprises using the indicia to properly orient the metallic food container prior to filling the metallic food container with food stuff. In some embodiments, the method further comprises interconnecting the bottom to the cylindrical sidewall.
In some embodiments, a metallic food container is provided comprising: a cylindrical sidewall with an upper end and a lower end; an opening proximate the upper end; a bottom portion interconnected to the lower end of the cylindrical sidewall, wherein the bottom portion comprises: a dome-shaped portion; and a well extending downward from the dome-shaped portion and extending around a circumference of the container, the well configured to receive a liquid.
In various embodiments, the well is directly interconnected to the cylindrical sidewall such that cylindrical sidewall is substantially vertical and terminates in the well formed by a radius of curvature, and the well comprises an inner well wall extending inward toward a center of the container from the well radius of curvature, wherein the well inner wall interconnects to the dome-shaped portion. In one embodiment, the metallic food container is a thin-walled metallic food container and the cylindrical sidewall has a thickness between about 0.003 inches and about 0.005 inches. In some embodiments, the metallic food container further comprises: a peripheral curl interconnected to the upper end of the sidewall; and a tear away lid secured to a crown of the peripheral curl. In one embodiment, the metallic food container further comprises: a neck extending from the upper end of the cylindrical sidewall and extending inwardly from the cylindrical sidewall; a peripheral curl interconnected to the neck; and a tear away lid secured to a crown of the peripheral curl. In additional or alternative embodiments, the metallic food container further comprises: a threaded portion positioned above the upper end of the sidewall, the threaded portion comprising a plurality of threads on an exterior surface of the threaded portion, wherein the threads are adapted to receive a threaded lid that is selectively removable; and a peripheral curl interconnected to an upper end of the threaded portion. In one embodiment, the metallic food container further comprises: a neck extending from the upper end of the cylindrical sidewall and extending inwardly from the cylindrical sidewall; and an end closure double-seamed to the neck of the container, the end closure having a pull tab for selectively removing at least a portion of the end closure. In one embodiment, the metallic food container further comprises: a neck extending from the upper end of the cylindrical sidewall and extending outwardly from the cylindrical sidewall; a first peripheral curl interconnected to the neck; and an upper portion comprising: a second peripheral curl on an upper end; a threaded portion positioned below the second peripheral curl, the threaded portion comprising a plurality of threads on an exterior surface of the threaded portion, wherein the threads are adapted to receive a threaded lid that is selectively removable; a countersink interconnected to a bottom end of the threaded portion; and a third peripheral curl interconnected to an upper outer end of the countersink; wherein the third peripheral curl of the upper portion is double seamed to the first peripheral curl. In some embodiments, the bottom portion is integrally interconnected to the lower end of the cylindrical sidewall such that the bottom portion is one piece with the cylindrical sidewall. In various embodiments, the dome-shaped portion has a hyperbolic paraboloid shape having a first curve with a first radius of curvature and a second curve with a second radius of curvature positioned substantially perpendicular to the first curve.
In various embodiments of the present invention, a pressurized metallic food container is provided comprising: a cylindrical, substantially vertical sidewall with an upper end and a lower end; a neck interconnected to the upper end of the sidewall and extending upwardly from the sidewall; an opening proximate the neck; and a bottom portion integrally interconnected to the lower end of the cylindrical sidewall, wherein the bottom portion comprises: a substantially linear outer panel wall extending downwardly from the sidewall; a U-shaped curved wall having a first radius of curvature and interconnected to a bottom portion of the outer panel wall; an inner panel wall extending upwardly from an interior portion of the U-shaped curved wall; and a dome-shaped portion with a first curve having a second radius of curvature, the domed portion interconnected to an uppermost portion of the inner panel wall at a third radius of curvature, wherein the outer panel wall, U-shaped curved wall, and inner panel wall form a well positioned around and concentric with the dome-shaped portion, and wherein the well is configured to receive a predetermined amount of liquid nitrogen.
In some embodiments, the inner panel wall is substantially linear, and the well has a constant height and a constant width around a circumference of the container. In various embodiments, the first radius of curvature is smaller than the second radius of curvature. In one embodiment, the domed portion has a hyperbolic paraboloid shape having a second curve with a fourth radius of curvature positioned substantially perpendicular to the first curve of the domed portion. In various embodiments, the metallic food container is a thin-walled metallic food container and the cylindrical, substantially vertical sidewall has a thickness between about 0.003 inches and about 0.005 inches.
In one embodiment of the invention, a method of manufacturing a metallic food container comprising: providing a metallic blank in a shape of a circular disc; punching the metallic blank to form a continuous sidewall with an upper end and a lower end and an opening proximate the upper end; and shaping a bottom portion interconnected to the lower end of the sidewall, wherein the bottom portion comprises a dome-shaped portion and a well positioned proximate to a lower portion of the dome-shaped portion to receive a liquid, and wherein the domed-shaped portion has a specific profile to match a profile of a food stuff.
In some embodiments, the method further comprises applying indicia to an exterior portion of the sidewall, wherein the indicia is provided for proper orientation of the metallic food container. In various embodiments, the method further comprises providing a lid; and securing the lid to the upper end of the continuous sidewall after the container is filled with food stuff to form a two-piece metallic food container.
In one embodiment of the present invention, a method of filling a metallic food container to create a pressurized vessel is provided, the method comprising: providing the metallic food container comprising: a cylindrical sidewall with an upper end and a lower end; an opening proximate the upper end; a bottom portion interconnected to the lower end of the cylindrical sidewall, wherein the bottom portion comprises: a dome-shaped portion with a geometric profile designed to nest with a food stuff; and a well positioned on a lower peripheral portion of the dome-shaped portion to receive a predetermined amount of liquid nitrogen; filling the metallic food container with the food stuff; injecting a predetermined amount of liquid nitrogen into the well of the container; and sealing the container with an end closure to pressurize the container above atmospheric pressure, wherein the liquid nitrogen becomes a gas as a result of a decrease in pressure or an increase in temperature.
In some embodiments, the pressure above atmospheric pressure is about 10 psi. In various embodiments, the liquid nitrogen is injected down into the well directly using a long needle-shaped tube. In one embodiment, the method further comprises forming a hyperbolic paraboloid shape in the dome-shaped portion. In some embodiments, the end closure is a metallic end closure double seamed to the upper end of the cylindrical sidewall, a paper or plastic tear away lid interconnected to the upper end of the cylindrical sidewall, or a screw-on lid interconnected to the upper end of the cylindrical sidewall. In one embodiment, the method further comprises sealing the container with the end closure within about 15 seconds after the predetermined amount of liquid nitrogen is injected into the well of the container.
In one embodiment, a method of filling a thin-walled metallic food container to create a pressurized vessel is provided, the method comprising: providing the thin-walled metallic food container comprising: a cylindrical sidewall with an upper end and a lower end, wherein the cylindrical sidewall has a thickness between about 0.003 inches and about 0.005 inches; an opening proximate the upper end; a bottom portion interconnected to the lower end of the cylindrical sidewall: filling the metallic food container with a dry food; injecting a predetermined amount of liquid nitrogen through the opening and into the bottom portion of the container; and sealing the container with an end closure to pressurize the container above atmospheric pressure, wherein the liquid nitrogen becomes a gas as a result of a decrease in pressure and/or an increase in temperature, and wherein the container has an internal pressure that is at least about 10 psi above an ambient pressure.
In some embodiments, the method further comprises forming a dome-shaped portion with a geometric profile designed to nest with the dry food in the bottom portion of the thin-walled metallic food container. In some embodiments, the method further comprises forming a well positioned on a lower peripheral portion of the dome-shaped portion, the well configured to receive the predetermined amount of liquid nitrogen. In various embodiments, the thin-walled metallic food container further comprises a well positioned on a peripheral portion of the bottom portion, the well configured to receive the predetermined amount of liquid nitrogen. In one embodiment, the end closure is a tear away lid secured to a top portion of the thin-walled metallic food container. In some embodiments, the method further comprises providing the thin-walled metallic food container comprising a threaded portion proximate the upper end of the cylindrical side wall, wherein the end closure is a screw-on lid that is screwed onto the threaded portion of the thin-walled metallic food container. In some embodiments, the method further comprises: providing a separate upper portion comprising threads and a peripheral curl; interconnecting the peripheral curl of the upper portion to the upper end of the cylindrical sidewall; and wherein the end closure is a screw-on lid that is screwed onto the threads of the upper portion. In various embodiments, the predetermined amount of liquid nitrogen is determined based on an amount of time between injecting the liquid nitrogen and sealing the container, a size of the thin-walled metallic food container, and a desired final internal pressure.
The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.
Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”.
The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more,” and “at least one” can be used interchangeably herein.
The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.
It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C. § 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the summary of the invention, brief description of the drawings, detailed description, abstract, and claims themselves.
These and other advantages will be apparent from the disclosure of the invention(s) contained herein. The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.
Those of skill in the art will recognize that the following description is merely illustrative of the principles of the invention, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this invention and is not meant to limit the inventive concepts disclosed herein.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of the invention.
Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.
The container 10 of
Note that the bottom portions 30 or bottom ends 26 disclosed and discussed in connection with
The sidewall 34 extends downward to the nitrogen well 82, which is formed by an outer well wall 70 (also called a “well outer sidewall”) interconnected to a curved portion 66 (also called a “well bottom”), which is interconnected to an inner well wall 74 (also called a “well inner sidewall”). In some embodiments, the lower end of the container sidewall 34 may not directly connect with the well outer sidewall 70. Thus, there may be a bump or curve or other extension or indentation portioned between the lower end of the container sidewall 34 and the well outer sidewall 70.
The inner well wall 74 is interconnected to the domed portion 78. The domed portion 78 of
The bottom end 26 of the container 10 of
Shown in dashed lines is a cross-sectional view of the bottom end 26 taken along a line that is perpendicular to the cut line 3-3. More specifically, the cross section shown in dashed lines is taken along the minor axis of the container 10 and is substantially perpendicular to the cross section shown in solid lines (i.e., the cross section showing R1). Thus, in this embodiment, the bottom 30 has two different domed portions 78, 102, each having a different curvature, as shown by the different cross-sectional views: a first downwardly-oriented curved domed portion 78 and a second upwardly-oriented curved domed portion 102. Here, the bottom 30 has a hyperbolic paraboloid shape.
The second (also called minor axis herein) domed portion 102 is the same as and matches the first (also called major axis herein) domed portion 78 along the concentric ring 122, which is also the well inner wall 74. At point 126, the second domed portion 102 diverges from the first domed portion 78. The second domed portion 102 extends upwardly forming a conical portion 106 that angles inwardly to the center of the container 10 to match the hyperbolic paraboloid shape of a crisps. The conical portion 106 meets the second radius of curvature R2 along the minor axis at the high points 110. The second radius of curvature R2 is oriented upwardly and extends from high point 110 to high point 110 to match the upwardly oriented radius of curvature of the crisps when the crisps are positioned with the major axis curvature facing the container bottom 26. At center point 118 the first radius of curvature R1 meets the second radius of curvature R2. Thus, point 118 is the lowest point of the second radius of curvature R2 and is the highest point of the first radius of curvature R1.
The dashed line shows the inner edge of the nitrogen well 82 according to some embodiments. In this embodiment, the nitrogen well is concentric with the container sidewall 34. However, in other embodiments, the nitrogen well 82 may not be concentric with the container wall and instead may be an oval shape similar to the oval shaped crisp 94. In some embodiments, the method of filling the container includes placing the crisps 94 inside the container 10 and then charging the liquid nitrogen and directing the liquid nitrogen flow into the area between the sidewall 34 and the crisps 94, i.e., into the nitrogen well 82, preferably in the portion of the well 82 between the sidewall 34 and the minor axis 146 of the oval crisp 94. This is because there is more space between the sidewall 34 and the minor axis 146 of the crisp 94 than there is between the sidewall 34 and the major axis 150 of the crisp. In some embodiments, the method of filling the container 10 includes charging the liquid nitrogen into the container 10, e.g., into the nitrogen well 82, before the food or crisps are placed into the container 10. Because the food is not yet in the container 10, the liquid nitrogen can be directed in any portion of the well 82. The well 82 prevents the crisps 94 from contacting the liquid nitrogen already in the container 10.
Note that the container 10 shape and proportions and chip 94 shape and proportions can vary in various embodiments. For example, in some embodiments, the container 10 has an oval shape and/or a larger nitrogen well. Additionally, the chips 94 may be circular or larger or smaller than shown. The chips 94 can also have different proportions between the major 150 and minor 146 axes. In some embodiments, there is more space between the chips 94 and the container sidewall 34, as shown in
In the embodiment shown, it is preferred to inject the liquid nitrogen between the minor axis of the crisp 94 (i.e., near the second centerline 170 of the container 10) and the sidewall 34. It is not preferred to inject the liquid nitrogen between the major axis of the crisp 94 (i.e., near the first centerline 166 of the container 10) and the sidewall 34.
The bottom end 226 of the container 210 of
As shown in
The screw-on lid 438 has a substantially flat upper surface 436 with a side portion 444 extending downwardly from and substantially perpendicular to the upper surface 436. The upper surface 436 is oriented in a substantially horizontal plane and the side portion 444 is oriented substantially vertically. The side portion 444 can include grooves 440 to aid a user in gripping the screw-on lid 438. Various embodiments can have more or fewer grooves 440 and the grooves 440 can have varying sizes. However, some embodiments do not include the grooves 440. The inner surface of the side portion 444 can have lugs that receive the threads 404 of the container.
Below the curl 516 is a threaded portion 502 having threads 504 and a substantially flat portion 506 between the threads 504. The threaded portion 502, which includes the flat portion 506, generally is positioned substantially vertically. The threads 504 can be embossed into the substantially flat portion 506 or otherwise stamped or pressed into the substantially flat portion 506. Alternatively, the threads 504 can be manufactured into the substantially flat portion 506 in any way known or used in the art. The upper portion 501 has a countersink 558 positioned between the threaded portion 502 and the peripheral curl 556. The neck portion 572 extends outwardly from the sidewall 534 such that it extends beyond (in the radial direction) the threaded portion 502, i.e., the outer diameter of the peripheral curl 556 of the main portion 500 is larger than the outer diameter of the threaded portion 502. The container 510 has a height H between about 3.0 inches and 13.0 inches in some embodiments. In preferred embodiments, the height H is about 3.438 inches, 7.50 inches, 9.1875 inches, or 11.50 inches. The container 510 has an outer diameter OD. In some embodiments, the outer diameter OD is between about 2.00 inches and about 4.00 inches. In preferred embodiments, the container outer diameter OD is about 2.8845 inches.
The container 510 can use the same screw-on lid as shown in
In some embodiments, when a screw-on lid is interconnected to the container, the outer diameter of the screw-on lid is the same as or less than the outer diameter of the double seamed peripheral curl 556 of the upper portion 501. Accordingly, the flared out neck portion 572 may be included, and thus sized and shaped, such that the outer diameter of the lid is the same as the outer diameter of the curl 556.
The container 610 has a ridge 680 positioned below the threaded portion 602, a groove 676 below the ridge 680, and then a neck 642 below the groove 676. The neck portion 642 is positioned between the threaded portion 602 and the sidewall 634, and more specifically between the groove 676 and the sidewall 634. The neck portion 642 tapers inwardly from the sidewall 634 to the groove 676. The sidewall 634 extends from the bottom portion 630 to the neck 642. The container 610 has a height H between about 3.0 inches and 13.0 inches in some embodiments. In preferred embodiments, the height H is about 3.438 inches, 7.50 inches, 9.1875 inches, or 11.50 inches. The container 610 has an outer diameter OD. In some embodiments, the outer diameter OD is between about 2.00 inches and about 4.00 inches. In preferred embodiments, the container outer diameter OD is about 2.8845 inches.
The screw-on lid 638 has a substantially flat upper portion 636 with a side portion 644 extending downwardly from and substantially perpendicular to the upper portion 636. The upper portion 636 is oriented in a substantially horizontal plane and the side portion 644 is oriented substantially vertically. The side portion 644 includes threads 698 to receive the threads 604 of the container 610 and to aid a user in gripping the screw-on lid 638. The threads 698 can be embossed into the side portion 644 or otherwise stamped or pressed into the side portion 644. Alternatively, the threads 604 can be manufactured into the side portion 644 in any way known or used in the art. The threads 604, 698 of both the container 610 and lid 638 can be various shapes and sizes, but the threads 604, 698 of both the container 610 and lid 638 must be shaped similar to one another to engage one another and function properly. The threads 698 of the lid 638 must be larger and/or longer than the threads 604 of the container 610 to permit the lid 638 to be unscrewed from the container 610. Moreover, the lid 638 may need to be flexible or bendable to permit the user to unscrew the lid 638 from the container 610 because of the shape and size of the threads 602, 698 on each. If the lid 638 bends or flexes as the user unscrews the lid 638 from the container 610, then the tamper band 696 may more easily detach from the lid 638. Alternatively, the lid 638 can have lugs on an inner surface of the side portion 644 that receive the threads 604 of the container.
The lid 638 also includes a tamper band 696 (also called a “tamper ring”) positioned below the side portion 644. Additionally, the lid 638 can include a neck portion 700 between the side portion 644 and the tamper band 696. In the embodiment shown, the neck portion 700 curves inward from the tamper band 696 to the side portion 644. The neck portion 700 is sized and shaped to accommodate the ridge 680 of the container 610. The tamper band 696 is separable from the lid 638 after the container 610 is opened for the first time. Thus, the tamper band 696 can be connected to the lid 638 via thin bridges or slits or perforations can be cut in between the lid 638 and the tamper band 696 after it is formed such that the tamper band 696 is frangible and separable from the lid 638. Thus, the thin bridges, slits, or perforations form an area of weakness such that the tamper ring 696 is easily separable from the lid 638 by a user. The tamper band 696 indicates to a consumer whether the container 610 has been opened previously.
The screw-on lid 638 is screwed onto the threaded portion 602 of the container 610. More specifically, the threads 698 on the lid's side portion 644 engage the threads 604 of the container 610 to securely seal the container 610. The upper portion 636 of the screw-on lid 638 is positioned on the peripheral curl 618 of the container 610. Thus, the diameter of the substantially flat upper portion 636 of the screw-on lid must be the same as the curl 618 outer diameter or slightly larger than the curl outer diameter. The tamper band 696 has a protrusion 697 that fits into the groove 676 of the container 610. The neck portion 700 of the lid 638 receives and ridge 680 of the container. The container's groove 676 and ridge 680 work in combination with the lid's neck portion 700 and perforations, bridges, or slits between the tamper band 696 and lid 638 to permit detachment of the tamper band 696 from the lid 638. Additionally, the container ridge 680 holds the tamper band 696 onto the container 610 even after the lid 638 has been removed from the container 610.
Note that the tamper band 696 of the present embodiment can be included in any other embodiment herein that includes a screw-on lid. For example, the tamper band 696 can be added to the lid 438 of
While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various ways. It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
This application claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 62/879,941, filed Jul. 29, 2019, entitled “Domed Container with Nitrogen Well”; the entire disclosure of which is hereby expressly incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62879941 | Jul 2019 | US |
