CONTAINER HAVING A CLOSURE AND REMOVABLE RESEALABLE STOPPER FOR SEALING A SUBSTANCE THEREIN, AND RELATED METHOD

Abstract

A container comprising a container body defining a storage chamber for receiving a substance and a container closure removably attached to the container body for sealing the storage chamber. The container closure includes a base defining an aperture in fluid communication with the storage chamber, and a needle penetrable and thermally resealable stopper overlying the aperture for aseptically filling the storage chamber with the substance and sealing the substance within the storage chamber with respect to the ambient atmosphere. A sealing portion engages the container body prior to filling and forms a substantially dry hermetic seal between the container closure and container body. The container further comprises an over closure engageable with the container closure such that removal or movement of the over closure from a first position to a second position results in substantially simultaneous removal of the container closure and stopper to allow dispensing of the substance.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 60/981,107, filed Oct. 18, 2007, which is hereby incorporated by reference in its entirety as part of the present disclosure.

FIELD OF THE INVENTION

The present invention relates generally to containers for storing and dispensing substances. More particularly, the invention relates to containers comprising container bodies and container closures that are penetrable by a filling member for filling the sealed container bodies with substances, such as beverage whiteners, and are thermally resealable for resealing the penetrated region of the container closures, and over closures that are engageable with the container closures and removable relative to the container bodies to remove the container closures from their respective container bodies.

BACKGROUND OF THE INVENTION

Prior art systems for aseptically filling containers with liquid products, such as beverage whiteners, produce containers having an open mouth and a peel-back foil or paper top that is secured to the open mouth after aseptically filling the containers with the product. FIGS. 1A and 1B illustrate a container typically produced by prior art systems. In many such systems, the containers are created by vacuum-sucking preformed rolls of stock into the desired shape, which are then pre-sterilized by flushing the interior and exterior surfaces of the open containers with a fluid sterilant, such as peroxide vapor or vaporized hydrogen peroxide (“VHP”), to sterilize the food contacting surfaces. Then, the containers are flushed with heated sterile air in order to re-vaporize any fluid sterilant that condenses on the container surfaces and to flush away the sterilant. After flushing with heated sterile air, the containers are filled through their respective open mouths with the desired product and, after filling, the containers are capped with a peel-back paper or foil cover to seal the product within the containers. Typically, the sterilizing, flushing, filling and capping processes are all performed within the same sterile zone of the filling system.

One of the drawbacks of this type of filling system is that it can be difficult to remove all of the fluid sterilant from the interior surfaces of the containers, thus leaving sterilant residue, such as hydrogen peroxide, within the containers and thereby contaminating the product filled into the containers. If the level of residue is sufficiently high, the product must be discarded. Alternatively, the sterilant residue can negatively affect the taste or taste profile of the product.

Another drawback is that filling the containers with a number of separate liquids, for example, to create containers holding liquids of varying flavors, can be cumbersome and prohibitively expensive, as many manufacturing assembly lines are currently designed to fill containers with one liquid at a time and, therefore, in order to fill containers with multiple liquids, such systems must be shut down, completely flushed out, cleaned, connected to a new liquid source and then started up again. Alternatively, multiple assembly lines may need to be built and set up for each desired liquid or flavoring, which would add to the overall manufacturing expense and complicate the filing and sterilization process.

Another drawback is that the sterilizing, flushing, filling and capping processes typically are all performed within the same sterile zone, and therefore the apparatus forming the sterile zone tends to be relatively large and complex. Moreover, because the product is open filled (i.e., poured into the open mouths of the containers), the product is not as well contained within the sterile zone as otherwise desired, thus creating unwanted spillage and waste within the sterile zone requiring additional clean-up. Cleaning such large and complex systems can result in substantial down time and expense, and as a result, such prior art systems can have undesirably short run times between cleaning and sterilization of the sterile zone. Further, if any part of the system goes down, the entire system must be subjected to clean in place (“CIP”) and sterilize in place (“SIP”) procedures prior to re-starting, which can further contribute to substantial down time and expense.

Another drawback is that the filled and sealed containers are often weak in strength, as are the peel-back foil or paper lids, which facilitates bursting or leaking and contributes to wasted product and/or undesirable manufacturing downtimes.

Yet another drawback is that the containers are filled immediately prior to capping resulting in poor container closure seals due to the presence of wet product at the sealing surfaces or interfaces.

Still another drawback is that, in many instances, product must be sterilized after the containers are filled by employing a retort process that can undesirably alter the taste of the product.

Another drawback is that the resulting sealed containers are small in size and, therefore, in certain instances contain an undesirably small serving of product. Consequently, consumers often use up multiple containers to satisfy their serving needs, which causes an unnecessary waste build-up of used containers.

Accordingly, it is an object of the present invention to overcome one or more of the above-described drawbacks and/or disadvantages of the prior art.

SUMMARY OF THE INVENTION

In accordance with a first aspect, the present invention is directed to a container comprising a container body defining a storage chamber therein for receiving a substance, a first aperture in fluid communication with the storage chamber, and a container closure for sealing the storage chamber. The container closure includes a container closure base defining a second aperture in fluid communication with the storage chamber, a closure stopper that overlies the second aperture and is penetrable by a filling member for aseptic filling through a filling member aperture formed therein, and a sealing portion engageable with the container body prior to aseptically filling the storage chamber with the substance. The sealing portion preferably forms a substantially dry hermetic seal between the container closure and container body. The container also includes an over closure engageable with the container closure, preferably after filling the container and thermally or otherwise sealing the filling member aperture. The over closure is removable relative to the container body to substantially simultaneously remove the container closure from the first aperture and allow the substance to be dispensed from the container.

In accordance with another aspect of the present invention, the container closure base defines a plurality of apertures angularly spaced relative to each other and extending about a periphery of the container closure base. Accordingly, the closure stopper material is allowed, during the molding process, to flow through the plurality of apertures and be received within an annular groove formed on an underside of the container closure base to, in turn, form an annular seal between the container closure and container body.

In accordance with another aspect, the over closure is pivotally secured to the container body and is movable between a first position and a second position relative to the container body. The over closure removes the container closure from the container body when the over closure is moved between the first and second positions. In accordance with another aspect, the over closure is connectable to the container body by a at least one frangible member for providing evidence of tampering and, in one such embodiment, a pull tab is connected to the frangible member for breaking the connection between the frangible member and the over closure. In some embodiments of the present invention, the frangible member is mechanically interconnected with the body to releasably secure the over closure to the body. In order to open the container, the frangible member is pulled away from the body to disconnect the frangible member from the body and, in turn, allow removal of the over closure and container closure from the body. In accordance with another aspect, the over closure is fixedly secured to the container closure and pivotally attached to the container body to remove the container closure from the first aperture and allow dispensing therethrough. In some embodiments of the present invention, the storage capacity of the container is within the range of about 15 ml to about 45 ml. In other embodiments of the present invention, the storage capacity of the container is within the range of about 25 ml to about 35 ml.

In accordance with another aspect, the present invention is directed to a method comprising the following steps: providing at least one container body defining a storage chamber therein for receiving a substance, and a first aperture in fluid communication with the storage chamber; a container closure removably attached to the container body for sealing the storage chamber, including a container closure base defining a second aperture in fluid communication with the storage chamber, a closure stopper overlying the second aperture and penetrable by a filling member through a filling member aperture therein for aseptically filling the storage chamber with a substance, such as a liquid product or products, wherein the filling member aperture is thermally resealable to seal the substance within the storage chamber with respect to the ambient atmosphere, and a sealing portion engageable with the container body prior to aseptically filling the storage chamber with the substance and forming a substantially dry hermetic seal between the container closure and container body. The method further includes providing at least one over closure engageable with at least one of the container closure and container body after filling and thermally resealing the filling member aperture, and removable relative to the container body, wherein removal of the over closure results in substantially simultaneous removal of the container closure from the first aperture to allow dispensing of the substance therethrough; and providing a first liquid source and a first filling member coupled in fluid communication with the first liquid source. The method further includes penetrating the stopper with the first filling member through the filling member aperture; introducing a first liquid component through the first filling member and into the storage chamber; withdrawing the first filling member from the storage chamber; thermally resealing the filling member aperture to hermetically seal the filled storage chamber with respect to the ambient atmosphere; securing the over closure to the container; and at least one of (i) removing the over closure and, with it, the container closure to expose the first aperture for dispensing product therethrough, and (ii) pivotally moving the over closure between a first position and a second position relative to the container body and, in turn, removing with the over closure the container closure from the container body as the over closure is moved from the first position to the second position.

In accordance with another aspect, prior to the resealing step, the method further comprises: providing at least one additional liquid source and at least one additional filling member coupled in fluid communication with the at least one additional liquid source in fluid communication with the storage chamber of the container through the first aperture, and aseptically introducing the at least one additional liquid component through the at least one additional filling member and into the storage chamber and, in turn, combining the first and the at least one additional liquid components into a liquid product formulation within the sterile chamber of the container.

One advantage of the present invention is that the product can be aseptically filled into sealed, empty sterile containers, thus avoiding the need to sterilize the product by retort after filling and the negative effects of retort on the filled product.

Another advantage of the present invention is that the stopper is sealed to the container body prior to filling the container, thereby forming a dry seal between the stopper and container body and avoiding the seal integrity problems encountered with “wet” seals in the prior art.

Another advantage of some embodiments of the present invention is that multiple products or product components may be aseptically filled into the same sealed, empty, sterile container at discrete time intervals, and the container and its contents remain sterile during the entirety of the process.

Another advantage of some embodiments of the present invention is that filling the containers with a number of separate liquids in the manner described, for example to create containers holding different flavors, is now possible in one assembly line.

Another advantage of the present invention is that removal of the over closure results in substantially simultaneous removal of the container closure and stopper thereby providing a convenient way of opening the container to dispense the substance without having to separately manipulate the container closure and stopper.

Other advantages of the present invention and/or of the currently preferred embodiments thereof will become more readily apparent in view of the following detailed description of the currently preferred embodiments and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are illustrations of prior art containers.

FIG. 2 is an elevational side view of a container embodying the present invention.

FIG. 3 is an elevational side view of a container embodying the present invention with the over closure removed to show the container closure.

FIG. 4 is a cross-sectional view of FIG. 2.

FIG. 5 is a partial, cross-sectional view of FIG. 3.

FIG. 6 is a top plan view of FIG. 3.

FIG. 7 is an upper perspective view of the container closure base.

FIG. 8 is a lower perspective view of the over closure assembled to the container closure and with the container body removed for clarity.

FIG. 9A is a side elevational view of another embodiment of the present invention showing the over closure in the first position.

FIG. 9B is a side elevational view of another embodiment of the present invention showing the over closure in the second position.

FIG. 10A is a somewhat schematic illustration of an exemplary apparatus and method of filling, sealing and opening the containers of the present invention.

FIG. 10B is a somewhat schematic illustration of an exemplary apparatus and method of filling, sealing and opening the containers of the present invention.

DETAILED DESCRIPTION OF CURRENTLY PREFERRED EMBODIMENTS

In FIGS. 2 through 8, a container embodying the present invention is indicated generally by the reference numeral 10. As shown best in FIG. 4, the container 10 comprises a container body 20 defining a storage chamber 22 therein for receiving a substance, and a first aperture 24 formed through the neck of the body 20 in fluid communication with the storage chamber 22. A container closure 30 is engageable with the container body 20 and overlies the first aperture 24 for hermetically sealing the storage chamber 22 with respect to the ambient atmosphere. In the illustrated embodiment, the container closure 30 is at least partially received within the first aperture 24 to form a dry hermetic seal between the container closure and body. The container 10 further includes an over closure 50 engageable with the container closure 30. The over closure 50 overlies the container closure 30 and engages the container closure such that removal of the over closure 50 results in substantially simultaneous removal of the container closure 30 from the container body 20. The over closure 50 also provides a tamper-resistant barrier to prevent the container closure 30 and stopper 34 (described in further detail below) from being removed and/or undesirably penetrated prior to dispensing of product from the container by an end user.

As shown in FIG. 3, the container closure 30 includes a container closure base 32 and a closure stopper 34. The container closure base 32 is connectable between the closure stopper 34 and container body 20 for securing the stopper to the container body 20. As shown in FIGS. 4 and 5, the container closure base 32 defines a second aperture 36 in fluid communication with both the first aperture 24 and the storage chamber 22 of the container 10. In the illustrated embodiment, the container closure base 32 is threadedly engageable with the container body 20. As shown typically in FIGS. 4, 5 and 8, the depending flange of the container closure base 32 defines a female thread 37 and the neck 33 of the container body 20 defines a male thread 39 that threadedly engages the female thread 37 to releasably secure the container closure to the body. When the container closure 30 is threadedly engaged to the neck 33 of the container body 20, the annular sealing member 35 is compressed between the land on the neck 33 and the container closure to form a dry hermetic seal between the container closure and body.

As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the container closure may be releasably connected to the container body in any of numerous different ways that are currently known, or that later become known. For example, the container closure base 32 may be engageable with the container body 20 through the interconnection of a series of recessed ridges on the container closure base and a series of raised ridges on the container body (or vice versa), or the container closure base 32 may be snap fit to the container body 20. As shown in FIG. 4, the closure stopper 34 is configured to overly the second aperture 36; however, in some embodiments, the stopper 34 may be at least partially received within the second aperture 36.

In a currently preferred embodiment of the invention, and as described in further detail below, the closure stopper 34 is penetrable by a filling member for aseptically filling the storage chamber 22 with one or more substances, and a resulting filling member aperture formed in the closure stopper 34 after withdrawing the filling member is thermally resealable to seal the substance within the storage chamber 22. It should be noted that the filling member can take on numerous forms, such as a needle, tube, spout, pipe, cannula or other devices that are currently known or that later become known for filling a container with substance. Also, the filling member aperture may take on any of numerous different forms, such as a needle hole, or if desired for higher volume filling, an axially elongated slit, or any of numerous other shapes or configurations that are currently known or that later become known. In the illustrated embodiment, and as shown best in FIGS. 4 and 5, the closure stopper 34 is approximately dome-shaped to compress itself inwardly and therefore naturally tend to close itself or be self sealing when a filling aperture is formed therein. Also in the illustrated embodiment, the closure stopper 34 is over molded to the container closure base 32 or otherwise is co-molded with the container closure base.

As shown in FIGS. 4-8, the closure base 32 defines two laterally extending flanges 42 located on substantially opposite sides of the container closure base relative to each other to facilitate connection of the over closure 50 to the container closure 30. As shown best in FIG. 8, the over closure 50 defines on the interior thereof two depending connecting flanges 43 located on diametrically opposite sides of the over closure 50 relative to each other, and forming two angularly-extending gaps 45 therebetween. Each connecting flange 43 defines a chamfered, inwardly projecting lip 47. As can be seen, in order to connect the over closure 50 to the container closure 30, the opposing flanges 42 of the container closure 30 are received within the respective angularly-extending gaps 45 of the over closure 50, and the undersides of the lips 30 of the connecting flanges 43 engage the bottom edge of the container closure base 32 to fixedly attach the over closure to the container closure. The chamfered lip 47 of each connecting flange 43 allows the connecting flanges 43 to flex outwardly and slide over the outer peripheral surface of the container closure base 32 in order to attach (or snap fit) the over closure 50 to the container closure 30. Accordingly, the over closure 50 is fixedly attached to the container closure 30 by sliding the over closure over the container closure and pressing down on the over closure until the chamfered lips 47 snap into engagement with the bottom edge of the container closure base 32. One advantage of this configuration is that it lends itself to automated attachment of the over closure 50 to the container closure 30 after aseptic filling of the container. For example, a fixture of a type known to those of ordinary skill in the pertinent art can be provided to snap fit the over closures 50 to the container closures 30 by a simple downward motion of the over closures onto the container closures. As described in further detail below, a frangible tamper ring 54 of the over closure 50 interlocks with the container body 20 upon attachment of the over closure 50 to the container closure 30 to, in turn, prevent rotation of the container closure 30 (and thus removal of the container closure) without removal of the frangible tamper ring. Yet another advantage of the currently preferred embodiments of the present invention is that the over closure 50 substantially simultaneously removes the container closure 30 away from the container body 20, thereby providing an easy and convenient way of opening the sealed container 10 during consumer use.

As shown best in FIG. 7, the container closure base 32 defines a plurality of through holes or apertures 38 angularly spaced relative to each other and extending about the periphery of the upper surface of the container closure base 32. Accordingly, the material of the closure stopper 34 is permitted to flow through the apertures 38 during the process of over molding or otherwise co-molding the stopper 34 to the closure base 32, and is received within an annular groove 40 (FIG. 5) formed on the underside of the closure base. Upon completion of the molding process, as shown typically in FIG. 5, the stopper material flows through the apertures 38 and into the annular groove 40, and the material disposed in the annular groove 40 forms an annular resilient seal 35 between the container closure 30 and the land on the neck 33 of the container body 20 when the container closure base 32 is engaged with the container body. The stopper 34 and integral annular seal 35 are made of a flexible or resilient material that forms a dry, compression, hermetic seal between the container closure and body. The container closure 30 further defines a depending annular flange 31 that is received within the aperture 24 of the neck 33 of the container body 20, and that slidably engages the interior of the neck upon attachment of the container closure to the body to thereby form a secondary seal between the container closure and body.

As indicated above, the over closure 50 is frangibly connected to the container body 20 to prevent rotation of the container closure 30 and thus prevent tampering with the contents of the container without breaking the frangible connection. As shown in FIGS. 2, 3, 4 and 8, the over closure 50 is frangibly connected with the container body 20 through the interaction of a series of raised ridges 52 (FIG. 8) on the over closure and a series of recessed ridges 26 (FIG. 3) on the container body 20. As shown in FIG. 8, the frangible ring 54 of the over closure 50 defines on the interior thereof a plurality of raised ridges 52 that are angularly spaced relative to each other about the interior periphery of the annular ring, and a plurality of recesses 53 formed between the raised ridges 52. Similarly, as shown in FIG. 3, the container body 20 defines at the base of its neck 33 a series of raised ridges 26 that are angularly spaced relative to each other about the base of the neck, and a plurality of recesses 27 formed between the raised ridges 26. Accordingly, when the over closure 50 is attached to the base 20, the raised ridges 52 of the over closure are received within the corresponding recesses 27 of the base, and the raised ridges 26 of the base are received within the corresponding recesses 53 of the over closure. Accordingly, the interlocking ridges and corresponding recess prevent relative rotation of the over closure 50 and container body 20, and thus prevent removal of the container closure 30 without breaking the tamper ring 54. As indicated above, the raised ridges 52 are formed along the frangible ring 54 extending about the base of the over closure 50. The frangible ring 54 is frangibly connected to the base of the over closure 50 at an annular, reduced cross-sectional thickness region 55. In order to remove the over closure 50 from the body 20, a user manually grasps the frangible ring 54 and pulls the ring away from the over closure and body. The manual force applied to the frangible ring 54 is sufficient to break the annular frangible connection 55 and, in turn, allow removal of the ring from the over closure. This, in turn, disengages the ridges/recesses of the frangible ring from the ridges/recesses of the body to thereby allow the over closure and container closure connected thereto to be detached from the body. In its unbroken state, the frangible member 54 provides a visual indication that the filled container 10 is properly sealed and has not been tampered with. In the illustrated embodiment, a pull tab 56 is connected to or otherwise formed integral with the frangible ring 54 for facilitating manual engagement of the ring by the pull tab and, in turn, breaking the connection between the raised ridges 52 on the over closure 50 and the recessed ridges 26 on the container body 20. In the absence of a pull tab, the frangible member 54 may be broken by a number of different methods known to those skilled in the art, such as, for example, by twisting or cutting. As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, the over closure 50 may be engageable with the container body 20 through any of a variety of different methods that are currently known or later become known to those skilled in the pertinent art. For example, the over closure 50 may be snap fitted to the container body 20, or the over closure 50 may be threadedly engageable with the container body 20.

Turning to FIGS. 9A and 9B, an alternative embodiment of a container of the present invention is indicated generally by the reference numeral 110. The container 110 is substantially the same as the container 10 described above in connection with FIGS. 1 through 8, and therefore like reference numerals preceded by the numeral “1” are used to indicate like elements. The primary difference between the container 110 and the container 10 is that the over closure 150 of the container 110 is pivotally secured to the container body 120 and movable relative to the container body 120 between a first position (FIG. 9A) and a second position (FIG. 9B). In this embodiment the container closure 130 is connected to the over closure 150 in the same manner as described above; however, the container closure 130 is not threadedly attached to the neck 133 of the container body 120. Accordingly, in the same manner as illustrated above, the depending flange 131 of the container closure 130 is received within the neck 133 of the container body 120 to form a secondary seal, and the annular seal 135 engages the land on the neck 133 to form a primary hermetic seal. If desired, the container closure 130 may be snap fit to the container body 120 in a manner known to those of ordinary skill in the pertinent art to facilitate releasably retaining the container closure to the container body, and to facilitate applying an appropriate degree of compression to the annular seal between the container closure and land on the neck of the container body. As shown in FIGS. 9A and 9B, in the first position, the over closure 150 pivotally connected to the container body 20 so that the stopper 134 overlies the second aperture 136 and the container closure 130 hermetically seals the substance in the storage chamber 122 from the ambient atmosphere. In moving the over closure 150 from the first position (FIG. 9A) to the second position (FIG. 9B), the container closure 130 is substantially simultaneously removed from and/or separated from the container body 120 with the over closure such that the stopper 134 is moved away from the second aperture 136 allowing the substance stored in the storage chamber 122 to be dispensed therefrom. One advantage of this embodiment is that it allows the user to flip the over closure 150 up and remove the container closure 30 with it; however, the over closure and container closure assembly remain pivotally attached to the body and thus do not require separate disposal. In addition, the pivotal attachment of the container closure and over closure assembly facilitates a user's ability to reseal any remaining product within the container and, for example, store the remaining product in a refrigerator for future use.

Having thus described the features of the containers 10 and 110, attention is now drawn to an apparatus and method for filling a plurality of the containers described above, or similar containers, with products that may include one or more product components. With reference to FIGS. 10A and 10B, the apparatus and method comprises the step of providing at least one container of any of the types, for example, described above. The sealed, empty containers define sterile chambers that are sealed with respect to ambient atmosphere. In some embodiments of the present invention, the sealed, empty containers are sterilized such as by apply radiation, such as gamma or ebeam radiation thereto. In other embodiments, the containers are molded and assembled, or molded such that the sealed, empty containers are formed with sterile empty chambers as described in the co-pending patent applications incorporated by reference herein below. The sealed empty containers are introduced into the enclosure 58 of a sterile filling machine. Preferably, the enclosure includes an overpressure of sterile air or other gas, such as micro-filtered air, to maintain a requisite level of sterility within the enclosure. The overpressure of sterile gas may be downwardly directed within the enclosure 58, may be horizontally or laterally directed, or may be directed in any combination of directions in the same or different locations within the enclosure. If desired, the enclosure may include a conveyor (not shown) for transporting the containers through the different stations within the enclosure. The sealed, empty, sterile containers may be introduced into the enclosure through a sterile filling port of a type known to those of ordinary skill in the pertinent art, or alternatively, the external surfaces of the sealed, empty sterile containers may be sterilized upon receipt within the enclosure, such as by applying VHP or other fluid sterilant to such surfaces in a manner known to those of ordinary skill in the pertinent art.

As shown in FIG. 10A, the filling process further comprises the step of providing a first liquid source 62 and a first filling member 60 coupled in fluid communication with the first liquid source 62. The first filling member 60 is movable vertically into and out of the engagement with the containers located below the filling member. The stopper 34 is then penetrated by the first filling member 60, such as a filling needle, and the first filling member forms a resultant filling member aperture in the stopper. Then, a first liquid component is aseptically introduced through the first filling member 60 and into the storage chamber 22, and the first filling member 60 is withdrawn from the storage chamber 22. The resulting filling member aperture is thermally resealed by application of laser radiation from laser source 70 to hermetically seal the filled storage chamber 22 (and the first liquid component stored therein) with respect to the ambient atmosphere. After filling, the over closure 50 is secured to the container.

To open a filled and sealed container to dispense the liquid, the consumer performs at least one of the following steps: (i) removes the over closure 50 and, with it, the container closure 30 to expose the first aperture 24 for dispensing product therethrough, and (ii) pivotally moves the over closure 150 between a first position and a second position relative to the container body 120 (as shown in FIGS. 9A and 9B) wherein the over closure 150 removes with it the container closure 130 from the container body 120 as the over closure 150 is moved from the first position to the second position.

In one embodiment of the invention, a plurality of additional filling members 61, 63 coupled in fluid communication with respective additional liquid sources 64, 66 are provided, wherein each source includes at least one respective additional liquid component. The additional liquid components are aseptically introduced via the respective additional filling members 61, 63 and into the storage chamber 22 and, in turn, are selectively combined with each other and/or the first liquid component to formulate a liquid product formulation within the sterile chamber of the container. The additional liquid components are added as desired without having to shut down the filling system or employ separately operative filling systems for each desired liquid or liquid component; i.e. one filling system or machine can be used to fill the containers with multiple liquids and any combination of liquids or liquid components. For example, as shown in FIG. 10A, a first container can be filled with a first liquid component 62 and a third liquid component 66, but not a second liquid component 64. As shown in FIG. 10B, on the other hand, a second container can be filled with the second liquid component 64 and the third liquid component 66, but not the first liquid component 62. In one such embodiment, the first and/or second liquid components are flavorings, such as mocha, hazelnut, vanilla, cappuccino, chocolate, fruit flavoring, combinations of these or any of numerous other flavorings that are currently known or that later become known, and the third liquid component is a base liquid, such as a beverage whitener, and/or other liquids containing milk, non-dairy creamer and/or soy. As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, this filling system can include any desired or otherwise required number of liquid sources, liquid components and respective filling members, and the containers can be filled with any one liquid component, any combination of selected liquid components or, if desired, all available liquid components.

Exemplary apparatus and methods for aseptically filling the containers of the present invention with one or more liquid components are disclosed in the following co-pending patent applications that are hereby expressly incorporated by reference in its entireties as part of the present disclosure: U.S. patent application Ser. No. 12/245,678, filed Oct. 3, 2008, entitled “Apparatus for Formulating and Aseptically Filling Liquid Products”; U.S. patent application Ser. No. 12/245,681, filed Oct. 3, 2008, entitled “Method for Formulating and Aseptically Filling Liquid Products”; and U.S. Patent Application Ser. No. 60/997,675, filed Oct. 4, 2007, entitled “Apparatus and Method for Formulating and Aseptically Filling Liquid Products”.

The containers of the present invention can be filled and thermally resealed in accordance with the teachings of any of the following patent applications and patents that are hereby incorporated by reference in their entireties as part of the present disclosure: U.S. patent application Ser. No. 11/339,966, filed Jan. 25, 2006, entitled “Container closure with Overlying Needle Penetrable and Thermally Resealable Portion and Underlying Portion Compatible with Fat Containing Liquid Product, and Related Method,” U.S. patent application Ser. No. 11/879,485, filed Jul. 16, 2007, entitled “Device with Needle Penetrable and Laser Resealable Method, and Related Portion”, which is a continuation of similarly titled U.S. patent application Ser. No. 11/408,704, now U.S. Pat. No. 7,243,689, issued Jul. 17, 2007, which is continuation of U.S. patent application Ser. No. 10/766,172 filed Jan. 28, 2004, entitled “Medicament Vial Having A Heat-Sealable Cap, And Apparatus and Method For Filling The Vial”, now U.S. Pat. No. 7,132,631, issued Apr. 25, 2006, which is a continuation-in-part of similarly titled U.S. patent application Ser. No. 10/694,364, filed Oct. 27, 2003, now U.S. Pat. No. 6,805,170, issued Oct. 19, 2004, which is a continuation of similarly titled co-pending U.S. patent application Ser. No. 10/393,966, filed Mar. 21, 2003, which is a divisional of similarly titled U.S. patent application Ser. No. 09/781,846, filed Feb. 12, 2001, now U.S. Pat. No. 6,604,561, issued Aug. 12, 2003, which, in turn, claims the benefit of similarly titled U.S. Provisional Application Ser. No. 60/182,139, filed Feb. 11, 2000; similarly titled U.S. Provisional Patent Application No. 60/443,526, filed Jan. 28, 2003; similarly titled U.S. Provisional Patent Application No. 60/484,204, filed Jun. 30, 2003; U.S. patent application Ser. No. 10/655,455, filed Sep. 3, 2003, entitled “Sealed Containers And Methods of Making And Filling Same”; U.S. patent application Ser. No. 10/983,178 filed Nov. 5, 2004, entitled “Adjustable Needle Filling and Laser Sealing Apparatus and Method; U.S. patent application Ser. No. 11/901,467 filed Sep. 17, 2007, entitled “Apparatus and Method for Needle Filling and Laser Resealing”, which is a continuation of similarly titled U.S. patent application Ser. No. 11,510,961 filed Aug. 28, 2006, now U.S. Pat. No. 7,270,158 issued Sep. 18, 2007, which is a continuation of similarly titled U.S. patent application Ser. No. 11/070,440 filed Mar. 2, 2005, now U.S. Pat. No. 7,096,896, issued Aug. 29, 2006; U.S. patent application Ser. No. 11/786,206, filed Apr. 10, 2007, entitled “Ready to Drink Container with Nipple and Needle Penetrable and Laser Resealable Portion, and Related Method”, U.S. Patent Application Ser. No. 60/983,153, filed Oct. 26, 2007, entitled “Ready to Feed Container with Drinking Dispenser and Sealing Member, and related Method”; U.S. patent application Ser. No. 11/933,300, filed Oct. 31, 2007, entitled “Device with Needle Penetrable and Laser Resealable Portion and Related Method”; U.S. patent application Ser. No. 11/515,162, filed Sep. 1, 2006, entitled “Sealed Containers and Methods of Making and Filling Same”; U.S. patent application Ser. No. 11/933,272, filed Oct. 31, 2007, entitled “Sealed Containers and Methods of Making and Filling Same”; U.S. patent application Ser. No. 10/833,371, filed Apr. 28, 2004, entitled “Container with Valve Assembly for filing and Dispensing Substances, and Apparatus and Method for Filling”; U.S. Application Ser. No. 60/471,592, filed May 19, 2003, entitled “Dispenser and Apparatus and Method for Filling a Dispenser”; U.S. Application Ser. No. 60/469,677, filed May 12, 2003, entitled “Dispenser and Apparatus and Method for Filling a Dispenser”; U.S. Patent Application Ser. No. 60/465,992, filed Apr. 28, 2003, entitled “Container with Valve Assembly for filing and Dispensing Substances, and Apparatus and Method for Filling”; U.S. patent application Ser. No. 11/949,087, filed Dec. 3, 2007, entitled “Device with Needle Penetrable and Laser Resealable Portion, and Related Method; and U.S. patent application Ser. No. 11/487,836, filed Jul. 17, 2006, entitled “Container With Valve Assembly For Filling And Dispensing Substances, and Apparatus And Method For Filling”.

In addition, the containers and container closures can be molded, or molded and assembled to, for example, create sealed, empty sterile containers, in accordance with the teachings of any of the following co-pending patents and patent applications that are hereby expressly incorporated by reference in their entireties as part of the present disclosure: U.S. patent application Ser. No. 11/074,513, filed Mar. 7, 2005, entitled “Apparatus for Molding and Assembling Containers with Stoppers and Filling Same”; U.S. patent application Ser. No. 11/074,454, filed Mar. 7, 2005, entitled “Method for Molding and Assembling Containers with Stoppers and Filling Same”; U.S. Patent Application Ser. No. 60/551,565, filed Mar. 8, 2004, entitled “Apparatus and Method for Molding and Assembling Containers with Stoppers and Filling Same”; U.S. patent application Ser. No. 11/374,522, filed Mar. 13, 2006, entitled “Sterile De-Molding Apparatus and Method”; U.S. application Ser. No. 11/582,291, filed Oct. 17, 2006, entitled “Sterile De-Molding Apparatus and Method”; U.S. Patent Application Ser. No. 60/727,899, filed Oct. 17, 2005, entitled “Sterile De-Molding Apparatus and method”; and U.S. Patent Application Ser. No. 60/104,649, filed Oct. 10, 2008, entitled “Co-Extrusion Blow Molding Apparatus and Method, and Sealed Empty Devices”.

In one embodiment of the invention, the stopper 34 (FIG. 5) is preferably made of a thermoplastic/elastomer blend, and may be the same material as those described in the pending patent applications and patents incorporated by reference above. Accordingly, in one such embodiment, the penetrable and thermally resealable stopper 34 is a thermoplastic elastomer that is heat resealable to hermetically seal the filling member aperture by applying laser radiation at a predetermined wavelength and power thereto. Further, the thermoplastic elastomer forming the stopper defines: (i) a predetermined wall thickness, (ii) a predetermined color and opacity that substantially absorbs the laser radiation at the predetermined wavelength and substantially prevents the passage of radiation through the predetermined wall thickness thereof, and (iii) a predetermined color and opacity that causes the laser radiation at the predetermined wavelength and power to hermetically seal the filling member aperture formed in the stopper 34 in a predetermined time period of less than or equal to about 5 seconds and substantially without burning the stopper 34.

In one embodiment of the invention, the stopper 34 is a thermoplastic elastomer that is heat resealable to hermetically seal the filling member aperture by applying laser radiation at a predetermined wavelength and power thereto. The thermoplastic elastomer includes: (i) a styrene block copolymer; (ii) an olefin; (iii) a predetermined amount of pigment that allows the stopper 34 to substantially absorb laser radiation at the predetermined wavelength and substantially prevent the passage of radiation through the predetermined wall thickness thereof, and hermetically seal the filling member aperture formed in the stopper in a predetermined time period of less than or equal to about 5 seconds; and (iv) a predetermined amount of lubricant that reduces friction forces at an interface of the filling member and the stopper during penetration thereof. In one such embodiment, the stopper 34 includes less than or equal to about 40% by weight styrene block copolymer, less than or equal to about 15% by weight olefin, less than or equal to about 60% by weight mineral oil, and less than or equal to about 3% by weight pigment and any processing additives of a type known to those of ordinary skill in the pertinent art. The term “pigment” is used herein to mean any of numerous different substances or molecular arrangements that enable the material or material portion within which the substance or molecular arrangement is located to substantially absorb laser radiation at the predetermined wavelength and, in turn, transform the absorbed energy into heat to melt the respective material forming the penetrable and thermally resealable portion or stopper and resealing an aperture formed therein.

In one embodiment of the invention, the stopper 34 is a thermoplastic elastomer that is heat resealable to hermetically seal the filling member aperture by applying laser radiation at a predetermined wavelength and power thereto. The thermoplastic elastomer forming the stopper includes (i) a first polymeric material in an amount within the range of about 80% to about 97% by weight and defining a first elongation; (ii) a second polymeric material in an amount within the range of about 3% to about 20% by weight and defining a second elongation that is less than the first elongation of the first polymeric material; (iii) a pigment in an mount that allows the stopper 34 to substantially absorb laser radiation at the predetermined wavelength and substantially prevent the passage of radiation through the predetermined wall thickness thereof, and hermetically seal a filling member aperture formed in the filling member penetration region thereof in a predetermined time period of less than or equal to about 5 seconds; and (iv) a lubricant in an amount that reduces friction forces at an interface of the filling member and second material portion during filling member penetration thereof.

In one embodiment of the invention, the pigment is sold under the brand name Lumogen™ IR 788 by BASF Aktiengesellschaft of Ludwigshafen, Germany. The Lumogen IR products are highly transparent selective near infrared absorbers designed for absorption of radiation from semi-conductor lasers with wavelengths near about 800 nm. In this embodiment, the Lumogen pigment is added to the elastomeric blend in an amount sufficient to convert the radiation to heat, and melt the stopper material, preferably to a depth equal to at least about ⅓ to about ½ of the depth of the filling member aperture, within a time period of less than or equal to about 5 seconds, preferably less than about 3 seconds, and most preferably less than about 1½ seconds. The Lumogen IR 788 pigment is highly absorbent at about 788 nm, and therefore in connection with this embodiment, the laser preferably transmits radiation at about 788 nm (or about 800 nm). One advantage of the Lumogen IR 788 pigment is that very small amounts of this pigment can be added to the elastomeric blend to achieve laser resealing within the time periods and at the resealing depths required or otherwise desired, and therefore, if desired, the stopper 34 may be transparent or substantially transparent. This may be a significant aesthetic advantage. In one embodiment, the Lumogen IR 788 pigment is added to the elastomeric blend in a concentration of less than about 150 ppm, is preferably within the range of about 10 ppm to about 100 ppm, and most preferably is within the range of about 20 ppm to about 80 ppm. In this embodiment, the power level of the 800 nm laser is preferably less than about 30 Watts, or within the range of about 8 Watts to about 18 Watts.

As may be recognized by those skilled in the pertinent art based on the teachings herein, numerous changes and modifications may be made to the above-described and other embodiments of the present invention without departing from its scope as defined in the appended claims. For example, the container closure, over closure and container body may be made of any of numerous different materials that are currently known, or that later become known for performing their functions and/or depending on the container application(s), including the product to be stored within the container. In addition, the container body and container closure may take any of numerous different shapes and/or configurations, and may be adapted to receive and store within the storage chamber or chambers any of numerous different substances or products that are currently known or that later become known, including without limitation, any of numerous different food and beverage products, beverage whiteners, and other liquids containing milk, non-dairy creamer, or soy, low acid or fat containing liquid products, such as milk-based products, including without limitation milk, evaporated milk, infant formula, growing-up milks, condensed milk, cream, half-and-half, yoghurt, and ice cream (including dairy and non-diary, such as soy-based ice cream), other liquid nutrition products, liquid healthcare products, juice, syrup, coffee, condiments, such as ketchup, mustard, and mayonnaise, and soup, and pharmaceutical products. In addition, the container may include more than one chamber, and if desired, may include more than one penetrable and thermally resealable portion in fluid communication with each such chamber for aseptically filling the respective chambers. The term “container” is used herein to mean without limitation any device that includes one more sealed or sealable chambers for receiving therein an aseptically or sterile filled product or other substance. Accordingly, this detailed description of preferred embodiments is to be taken in an illustrative, as opposed to a limiting sense.

Claims

1. A container comprising:

a container body defining a storage chamber therein for receiving a substance and a first aperture in fluid communication with the storage chamber;

a container closure removably attached to the container body for sealing the storage chamber, including: a closure base defining a second aperture in fluid communication with the storage chamber; a closure stopper overlying the second aperture that is penetrable by a filling member for aseptically filling the storage chamber with the substance, and is thermally resealable after withdrawing the filling member therefrom to seal the substance within the storage chamber with respect to the ambient atmosphere; and a sealing portion engageable with the container body prior to aseptically filling the storage chamber with the substance and forming a substantially dry hermetic seal between the container closure and container body; and

an over closure engageable with the container closure after filling and thermally resealing the closure stopper and forming an over closure and container closure assembly, wherein the over closure and container closure assembly is manually engageable and movable between (i) a closed position wherein the sealing portion of the container closure is engaged with the body and forms a hermetic seal between the container closure and body, and (ii) an open position wherein the container closure is moved away from the body and the first aperture and storage chamber are open to ambient atmosphere to allow dispensing of the substance therethrough.

2. A container as defined in claim 1, wherein the closure stopper is at least one of (i) co-molded with the closure base and (ii) over molded to the closure base.

3. A container as defined in claim 1, wherein the closure stopper is approximately dome-shaped to compress itself inwardly.

4. A container as defined in claim 1, where at least one of the over closure and the container closure defines a relatively recessed surface, and at least one of the over closure and the container closure defines a relatively raised surface that is received within the relatively recessed surface to connect the over closure to the container closure.

5. A container as defined in claim 4, wherein the over closure includes at least one flange that defines at least one of the relatively raised and relatively recessed surfaces that engages the container closure to connect the over closure to the container closure.

6. A container as defined in claim 1, wherein the container closure includes an annular sealing member that forms a dry hermetic seal between the container closure and body, and is formed integral with the closure stopper.

7. A container as defined in claim 6, wherein the container closure defines a plurality of apertures angularly spaced relatively to each other and extending through a wall of the closure base, the closure base defines an annular groove in communication with the apertures, and the stopper material extends through the plurality of apertures and into the annular groove, and forms within the annular groove the annular sealing member.

8. A container as defined in claim 1, wherein at least one of: (i) the container body is threadedly engageable with the container closure base; (ii) the container closure base is rotatably engageable with the container body; and (iii) at least one of the container body and container closure base defines a relatively raised surface, and at least one of the other of the container body and the container closure base defines a relatively recessed surface for receiving therein the relatively raised surface and releasably connecting the closure base and container body.

9. A container as defined in claim 8, wherein the over closure is fixedly connected to the container closure, and is frangibly connected to the container body.

10. A container as defined in claim 9, wherein the container closure is rotatably engageable with the container body, and the frangible connection between the over closure and container body prevents relative rotation of the container closure and body.

11. A container as defined in claim 10, wherein the over closure includes a substantially ring-shaped portion that is frangibly connected to the over closure, and at least one of the ring-shaped portion and the body defines a plurality of relatively raised surface areas, and at least one of the other of the ring-shaped portion and the body defines a plurality of relatively recessed surface areas, wherein the raised surface areas are received within respective recessed surface areas to prevent relative rotation of the over closure and container closure assembly and the body.

12. A container as defined in claim 1, wherein the over closure is pivotally secured to the container body and movable between a first position and a second position relative to the container body, the over closure removing the container closure from the container body when the over closure is moved from the first position to the second position.

13. A container as defined in claim 1, wherein the storage capacity of the container is in the range of about 15 ml to about 45 ml.

14. A container comprising:

first means for forming a sealed, empty storage chamber therein for receiving a substance;

second means removably attachable to the first means for sealing the storage chamber, wherein the second means includes third means that is penetrable by a filling member for aseptically filling the storage chamber therethrough and is thermally resealable after removing the filling member therefrom for sealing the aseptically filled substance within the storage chamber; and fourth means engageable with the first means prior to aseptically filling the storage chamber with the substance and for forming a substantially dry hermetic seal between the second means and the first means; and

fifth means for engaging the second means after filling and thermally resealing the third means for enclosing the third means therein and for forming an interconnected assembly of the second means and the fifth means, wherein the interconnected assembly is manually engageable and movable between (i) a closed position wherein the fourth means is engaged with the first means for forming the hermetic seal therebetween, and (ii) an open position wherein the interconnected assembly of the second means and fifth means is moved away from the first means and storage chamber are open to ambient atmosphere to allow dispensing of the substance therethrough.

15. A container as defined in claim 14, wherein the first means is a container body; the second means is a container closure; the third means is a penetrable and thermally resealable stopper; the fourth means is a sealing member; and the fifth means is an over closure.

16. A container as defined in claim 14, further comprising sixth means for frangibly connecting the fifth means to the first means and for preventing tampering with the second means.

17. A method comprising the following steps:

providing at least one container body defining a storage chamber therein for receiving a substance and a first aperture in fluid communication with the storage chamber; a container closure removably attached to the container body for sealing the storage chamber, including a container closure base defining a second aperture in fluid communication with the storage chamber, a closure stopper overlying the second aperture and penetrable by a filling member for aseptically filling the storage chamber with the substance, and wherein a resulting filling member aperture formed therein is thermally resealable to seal the substance within the storage chamber with respect to the ambient atmosphere, and a sealing portion engageable with the container body prior to aseptically filling the storage chamber with the substance and forming a substantially dry hermetic seal between the container closure and container body;

providing at least one over closure engageable with the at least one container closure and container body after filling and thermally resealing the filling member aperture, and removable relative to the container body, wherein removal of the over closure results in substantially simultaneous removal of the container closure from the first aperture to allow dispensing of the substance therethrough;

providing a first liquid source including a first liquid component and a first filling member coupled in fluid communication with the first liquid source;

penetrating the stopper with the first filling member and forming the filling member aperture;

introducing the first liquid component through the first filling member and into the storage chamber;

withdrawing the first filling member from the storage chamber;

thermally resealing the filling member aperture to hermetically seal the filled storage chamber with respect to the ambient atmosphere;

securing the over closure to the container; and

at least one of (i) removing the over closure and, with it, the container closure to expose the first aperture for dispensing product therethrough, and (ii) pivotally moving the over closure between a first position and a second position relative to the container body, the over closure removing the container closure from the container body as the over closure is moved from the first position to the second position.

18. The method as described in claim 17, wherein the substance is at least one of a beverage whitener and flavoring.

19. A method as described in claim 17, wherein prior to the resealing step, the method further comprises:

providing at least one additional liquid source and at least one additional filling member coupled in fluid communication with the at least one additional liquid source in fluid communication with the storage chamber of the container; introducing the at least one additional filling member through the first aperture; aseptically introducing the at least one additional liquid component through the at least one additional filling member and into the storage chamber; and, in turn, combining the first and the at least one additional liquid components into a liquid product formulation within the sterile chamber of the container.

20. A method as described in claim 19, further comprising the steps of:

mounting the at least one container on a conveyor belt; and

mounting the first and at least one additional filling members at discrete stations above the conveyor belt.

21. A method as described in claim 19, wherein the first liquid component is a first flavor, one of the at least one additional liquid components is a second flavor, and one of the at least one additional liquid components is a base beverage whitener.

22. A method comprising the following steps:

(i) providing a sealed, empty container, defining a sterile chamber, an opening to the sterile chamber, and a container closure that is detachably connected to the container and seals the sterile chamber with respect to ambient atmosphere;

(ii) penetrating a penetrable and thermally resealable portion of at least one of the container and container closure with a filling member, aseptically filling the sterile chamber with at least one liquid through the filling member, withdrawing the filling member from the penetrable and thermally resealable portion, and thermally resealing a resulting filling member aperture and hermetically sealing the aseptically filled liquid within the sterile chamber;

(iii) attaching an over closure to the closure that encloses the penetrable and thermally resealable portion and forms an interconnected over closure and closure assembly.

23. A method as defined in claim 22, further comprising the step of manually engaging the over closure and substantially simultaneously removing the over closure and closure to open the container and dispense the liquid therefrom.

24. A method as described in claim 22, wherein step (ii) includes penetrating the penetrable and thermally resealable portion of at least one of the container and container closure with a plurality of different filling members, aseptically filling the sterile chamber with a plurality of different liquids through the different filling members, and thermally resealing any resulting filling member apertures and hermetically sealing the plurality of aseptically filled liquids within the sterile chamber.

25. A method as described in claim 24, wherein one liquid is a base beverage liquid, and another liquid is at least one of a flavoring and a coloring.