GLASS CONTAINER WITH ROLL-ON CLOSURE

Abstract

A glass container in the form of a growler is provided with a re-sealable roll-on closure. An improved construction is provided for the container enabling it to handle higher pressures in which minimum glass wall thicknesses are optimized to provide necessary strength for the container, yet the construction conserves amounts of glass used. In a preferred embodiment, the container is capable of holding a 64 oz beverage, and the container includes a re-sealable roll-on 38 mm closure with a capacity to hold up to 3.00 v/v CO2 pressure at 145° F. A minimum glass wall thickness along a sidewall of the container starting from a mid-neck down to a heel portion of the container is 2.5 mm. An integral glass handle is provided with a minimum break strength of 170 pounds. In a preferred embodiment, the container has a maximum to minimum sidewall thickness ratio of approximately 2:1 and a base thickness ratio of approximately 1.5:1.

Description

FIELD OF THE INVENTION

The invention relates to glass containers, and more particularly, to glass containers designed to hold carbonated beverages at relatively high pressures, including a roll-on cap or crown used to effectively seal the container to prevent leakage after opening.

BACKGROUND OF THE INVENTION

Glass or ceramic jugs, often referred to as “growlers”, have traditionally been used to hold malt beverages such as beer that has been brewed in small craft breweries. Prior to the advent of large commercial breweries, most malt beverages were sold by small local breweries that had little or no bottling capabilities. The growlers were used to allow customers to purchase beverages from the brewery and take home the beverages in relatively large containers that could then be poured later into individual glasses for consumption. The most popular size for growlers is the ½ US gallon (1,900 ml); however there are other growler sizes that are well-known to include 1 gallon sizes and ¼ gallon sizes. The most common type of handle for growlers is an integral glass handle; however, metal handles have also been used in more ornate growler designs.

Recently, there has been a resurgence in craft breweries. While bottling capabilities may now be more available to smaller craft breweries, many of these breweries have opted for continued use of the growler type container for historical and marketing purposes. Additionally, many larger breweries have entered into the craft brewery market, and have also chosen in some circumstances to use the growler container for marketing purposes. Regardless of the specific reason for current use of growlers, there continues to be certain advantages and disadvantages associated with the use of these types of containers.

One of the advantages of the growler is that it has a storage capacity for holding a quantity of a beverage that is likely to be consumed by the consumer within a relatively short period of time, thereby enabling the consumer to purchase a convenient bulk sized quantity without having to purchase a much larger keg sized quantity that likely would not be consumed by the consumer without significant waste. Another advantage is that the growler provides an economical solution for storage and distribution of the beverage, and can be more cost effective than use of multiple containers, such as 12 ounce glass containers.

There are a number of disadvantages associated with growlers. One clear disadvantage is that unless the beverage is consumed within a short period of time, the growler is incapable of maintaining adequate pressure within the container to keep the beverage adequately carbonated. Accordingly, the beverage soon loses carbonation and goes “flat”, which is a condition which most beer consumers agree is inadequate for consumption of the product. Another disadvantage is that, although many growlers are intended to be reused, they are difficult to adequately clean and sterilize because of the relatively small size of the container mouth. The small size of the opening makes accessing the relatively large interior volume for cleaning and sterilization difficult. The small size of the opening can also cause a vacuum or “glugging” when the beverage is being poured from the growler, resulting in an inadequate pour.

Yet another clear disadvantage of traditional growlers is that the glass material is fragile as compared to metal containers, and therefore the growlers with their relatively large size are particularly prone to breakage. Glass continues to be a preferred type of container material for consumers as compared to metal containers; many consumer tests show that a significant number of consumers believe the taste of a beverage is compromised if stored and dispensed from a metallic container. Further, sunlight can easily damage a stored beverage, and growlers exposed to sunlight increase the chance that the beverage will be consumed in a flavor degraded state. Some malt beverages are particularly sensitive to sunlight and can quickly degrade after even relatively short periods of sunlight exposure.

Therefore, there is a need to provide a relatively large sized glass container that can hold a carbonated beverage such as beer at adequate carbonation levels in which the container has the ability to withstand greater internal pressures and hold those pressures for an extended period of time to prevent the beer from going flat. Further, there is a need to provide such bulk sized glass containers that may be more easily cleaned. Further, there is a need to provide such bulk sized glass containers that allow the beverage to be more easily poured to create the characteristic “head” when the beverage is poured.

SUMMARY OF THE INVENTION

In accordance with the present invention, a glass container with a re-sealable roll-on cap is provided. The container also provides a design in which the container is capable of withstanding relatively high pressures to maintain a carbonated beverage stored within the container at desired carbonation levels thereby maximizing beverage consumption characteristics.

According to a preferred embodiment, the container includes a re-sealable roll-on 38 mm closure that achieves two distinct benefits. First, the 38 mm closure is considered sized for a “wide-mouth” opening, and is therefore larger than traditional closure sizes. The larger sized opening for the glass container allows for easier access to the interior space of the container for cleaning and sterilization purposes. Second, the 38 mm sized opening allows for better pourability of the beverage to avoid the vacuum or “glug” associated with smaller sized openings. This vacuum or “glug” inhibits a smooth pouring action, and can prevent the consumer from pouring a desired sized head of the malt beverage. It is well known that for malt beverages, some amount of head is desirable for both taste and product presentation purposes.

Also according to a preferred embodiment, an improved construction is provided enabling the container to handle higher pressures in which the minimum glass wall thicknesses are optimized to provide the necessary strength for the container, yet conserve the amount of glass used. The minimum glass wall thickness along a portion of the container starting from the mid-neck down to a heel portion of the container is 2.5 mm. However, the average preferred thickness may vary as described below in the detailed description, which also provides additional benefits with respect to various loading conditions and manufacturability.

Further in accordance with a preferred embodiment, an integrated glass handle is provided with a minimum break strength that exceeds normal break strength requirements for similar glass containers.

With respect to pressure requirements, the preferred embodiment provides for a container to hold 64 fluid ounces (or ½ gallon) of beverage in which the container is able to withstand at least 3.0 volumes of CO₂ per volume of beer and internal beer temperatures up to 145° F. for pasteurization. At the container manufacturing location, a theoretical pressure strength of the containers is set for approximately 225 psi interior pressure taking into account a factor of safety for loss in container strength. More specifically, during handling of containers at the manufacturing location, the containers inherently lose strength through contact or “bruising”, and therefore testing is conducted to confirm pressure strength when the containers are ready for shipment. The containers at this stage preferably must pass a pressure test for pressures greater than 150 psi over a one minute testing period. As the containers are further handled during shipment, there can be additional loss in strength and therefore, the containers undergo a further strength test at the filling location, such as a brewery, in which a minimum strength of greater than 100 psi must be achieved. A failure at this stage typically results in rejection of the lot or group of containers corresponding to the failed test sample container(s).

With respect to the roll-on 38 mm closure, the closure is designed to hold up to 3.00 v/v CO₂ pressure at 145° F. With respect to the break strength for the glass handle, the design of the present invention provides for a minimum break strength of 170 pounds. General dimensions for the container are such that container is capable of being handled by many standard bottle filling production lines. In a preferred embodiment, the height of the container is a minimum of 11.00 inches, the maximum diameter is less than or equal to 5.20 inches, and the bearing surface is approximately 4.0 inches in diameter.

Considering the above features of the invention, in one aspect the invention can be considered a glass container comprising: (i) a top portion including an opening; (ii) a base; (iii) a sidewall interconnecting the top portion and base; (iv) a 38 mm roll-on closure covering said opening; (v) a handle mounted to said container, wherein the sidewall has a minimum thickness of 2.5 mm and an average thickness of 4.5 mm to 5.5 mm, and wherein said container is sealed to hold up to 3.0 v/v CO₂ pressure at 145° F.

In another aspect of the invention, it can also be considered a glass container comprising: (i) a top portion including an opening; (ii) a base; (iii) a sidewall interconnecting the top portion and base; (iv) a 38 mm roll-on closure covering said opening; (v) a handle mounted to said container; wherein said container is sealed to hold up to 3.0 v/v CO₂ pressure at 145° F., and wherein said sidewall of said container has a preferred maximum to minimum thickness ratio of approximately 2:1.

In yet another aspect of the invention, it can also be considered a glass container comprising: (i) a top portion including an opening; (ii) a base; (iii) a sidewall interconnecting the top portion and base; (iv) a 38 mm roll-on closure covering said opening; (v) a handle mounted to said container; and wherein said container has a glass thickness distribution including: (a) a minimum thickness of 2.5 mm; (b) an average thickness of said sidewall of 4.5 mm to 5.5 mm; (c) said container has a heel located between the sidewall and base, said heel having an average thickness of 4.0 to 5.0 mm; and (d) said base includes a bearing surface formed along a peripheral portion of the base, said bearing surface having an average thickness of 6.5 to 7.5 mm.

Other features and advantages of the invention will become apparent from a review of the following detailed description, taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustrating the glass container of the present invention;

FIG. 2 is a side elevation view of the glass container of FIG. 1;

FIG. 3 is a vertical section taken along line 3-3 of FIG. 2;

FIG. 4 is an enlarged fragmentary perspective view of the upper portion of the container and a blank disposed above the upper end or finish of the container, the blank representing a closure or cap prior to be formed around the threads of the finish;

FIG. 5 is another enlarged fragmentary perspective view of the upper portion of the container showing the closure placed over the threads of the upper end of the container; and

FIG. 6 is a table providing information regarding a preferred thickness distribution for the container according to a preferred embodiment.

DETAILED DESCRIPTION

Referring to FIGS. 1-3, a container 10 of the present invention shown. The container 10 can be referred to as a growler, a container sized for holding a bulk volume of a beverage, and especially adapted for holding carbonated beverages such as beer. The container has a sidewall 12, a shoulder 14 disposed above an upper portion 16 of the sidewall, a converging portion 18, and a neck 20 disposed above the converging portion 18. The upper end of the container, also referred to as the finish 22, has threads 24 formed thereon. An integral handle 26 is provided, the handle 26 having an upper end 28 that attaches to the neck 20 at a base 31, and a lower end 30 that attaches to the converging portion 18 at base 31. The bases 31 of the upper and lower ends 28, 30 of the handle 26 are enlarged as shown which contributes to the increased break strength, as discussed below. The loop 27 of the handle is adequately sized for carrying, and the loop 27 creates an arcuate shaped opening 29 for use as a carrying handle.

The sidewall 12 may be further described as including the upper portion 16, a mid portion 32, and a lower portion 34. The sidewall 12 forms a cylindrical shape. Below the sidewall 12 is a converging heel 36 that terminates at a bearing surface 38. The bearing surface 38 is the exposed lower surface of the container that makes contact with the object on which the container is placed. The lower end of the container has a concave shape, and a center bottom portion 40 of the lower end corresponds to a small circular area centered on the lower end having a diameter of approximately 1 inch. Surrounding the center bottom portion 40 is the mid-bottom portion 42, defined by the area between the bearing surface 38 and the small circular area defining the center bottom 40.

In the preferred embodiment, the diameter of the container as measured from the diameter of the sidewall is less than or equal to 5.20 inches. The bearing surface defines a smaller diameter area of less than or equal to 4.00 inches. The overall height of the container in the preferred embodiment is a minimum of 11 inches.

Referring to FIG. 4, the container 10 is shown along with a blank or unthreaded shell 50 that is formed into a cap or closure in a subsequent capping process. More specifically, a roll-on type closure is initially provided as the blank 50, and when the container passes a capping station during a filling process, the blank 50 is compressed to conform to the finished shape of the upper end of the container. The blank 50 is made from a compressible metal, such as aluminum. The interior upper planar surface of the blank 50 has a compressible seal or liner (not shown) attached thereto. A capping machine (not shown) exerts a downward pressure that creates a positive seal on the liner of the blank 50 as the liner is pressed against the upper surface of the finish 22. Next, rollers on a capping head of the capping machine shape the malleable blank 50 to conform to the exact contour of the threads 24 on the container.

As shown in FIG. 5, the blank 50 has been compressed to form the cap or closure 52 with threads that match the threads 24 of the finish 22. According to the preferred embodiment, the container includes a re-sealable roll-on 38 mm closure that achieves two distinct benefits: the 38 mm closure is larger than traditional sizes of closures used on growlers and therefore allows for easier access to the interior of the container for cleaning and sterilization purposes, and second, the 38 mm sized opening allows for better pourability of a beverage from the container. Particularly for malt beverages, the larger size mouth of the container provides a better opportunity for air to enter the container as the beverage is poured from the container, therefore avoiding a vacuum or “glug” as the beverage is poured. The container in other words can be held at a larger range of angles when pouring to avoid the vacuum effect.

An improved construction is provided for the container enabling it to handle higher pressures in which the minimum glass wall thicknesses are optimized to provide the necessary strength for the container, yet conserve the amount of glass used. Through extensive testing, glass thickness distribution was modified in the present invention in order to provide a container that could handle increased pressure requirements, yet still resulted in an economic container that did not require excess amounts of glass material. Through this testing, it was determined that a ratio could be developed with regard to preferred minimum and maximum glass thickness distributions that met minimum strength requirements, but also met bottling and material requirements that limit the thickness of the container. For example, a container having an excessively thick sidewall may not meet required container dimension specifications, or may not meet required volume specifications, such as overflow capacity, in which case the thickened sidewall results in an incrementally smaller interior volume. For the sidewall area of the container, it was determined that a ratio of 2.0 to 1.0 (2:1) was preferable with respect to glass thickness in which the minimum allowable thickness was 2.5 mm. For the base area of the container, it was determined that a ratio of 1.5 to 1.0 (1.5:1) was preferable with respect to glass thickness in which the minimum allowable thickness was 5.1 mm. This base area of the container includes the center bottom 40, mid-bottom 42, and bearing surface 38 areas. As mentioned, one distinct disadvantage associated with growlers is that the containers do not have the capability to hold pressure with a re-sealable roll-on closure to facilitate acceptable carbonation levels for a stored beverage. Prior art growlers may include threaded closures, but not roll-on type closures with liners that provide a pressurized sealing capability. The preferred embodiment of the present invention provides for a glass container to accommodate a 64 ounce or ½ gallon beverage in which the container is able to withstand at least a 225 psi interior pressure.

As is well known with malt beverages, adequate levels of carbonation are critical for achieving the body or “fullness” of the beverage. Carbonation also provides the foaming capability and contributes as an important flavor component. Carbonization of a malt beverage is achieved in part through the brewing process. Carbonation levels are typically raised for the malt beverage prior to bottling in a forced carbonation step, providing necessary carbonation levels for sale of the beverage. One industry standard measure of carbonation is a measure of volumes of carbon dioxide per volume of beer, expressed as a ratio “v/v”. For bottled and canned beverages (12 or 16 oz sizes), the carbonation levels may typically be between 2.2 and 2.8 v/v. However, for growlers, maximum carbonation levels are typically about 2.0 v/v. This level of carbonation is clearly inadequate for any long term storage of a beverage. Further as mentioned, prior art growlers are not pressure sealed to the same capability as smaller 12 oz. containers, and therefore, optimum carbonation is lost prior to opening of the growler in many instances. Once a prior art growler is opened, carbonation levels quickly drop and unless the beverage is entirely consumed, the remaining beverage goes flat within a short period of time.

Due to the specific design of the glass wall thicknesses along with use of the re-sealable 38 mm closure, the container of the present invention is capable of holding and maintaining carbonation levels up to 3.00 v/v CO₂ at 145° F. At this level of carbonation, the beverage stands a much better chance of maintaining an optimum level of carbonation even after the container is opened. Since the container is re-sealable, the rate at which carbonation is lost is greatly slowed as compared to the prior art growlers. Therefore, the container of the present invention provides a solution for maintaining optimum levels of beverage carbonation, as well as to extend the shelf life of the beverage with the increased level of carbonation maintained.

The minimum glass wall thickness along the portion of the container defined from the neck 20 down to the heel 36 is 2.5 mm. However, the average preferred thickness varies as set forth in the table of FIG. 6. Referring to this table, ranges for average preferred thicknesses for the discrete portions or sections of the container are listed, along with minimum required thicknesses for most of the listed portions. Accordingly, in another aspect of the invention, an average thickness is also contemplated as a measured parameter with respect to thicknesses of the container 10. These average thicknesses are achieved through a container forming process in which the average thicknesses comply with the required minimum thicknesses, yet still enable the container to be manufactured in standard glass manufacturing processes having inherent limitations regarding how thin glass can be distributed without unacceptable numbers of manufacturing defects. For example, while the minimum required thickness for the container may be 2.5 mm for the sidewall 12, actually consistently achieving this minimum thickness in standard glass manufacturing processes is difficult; therefore, a factor of safety is added in the manufacturing process which inherently results in average thicknesses being greater than minimum required thicknesses. Again through testing, it was found that having the listed average thicknesses according to the table of FIG. 6 results in overall manufacturing benefits in which required glass distribution can be achieved through standard glass manufacturing processes, and therefore still results in significant savings of glass.

Further in accordance with the preferred embodiment, the integrated glass handle 26 is provided with a minimum break strength that exceeds normal break strength requirements for similar glass containers. One acceptable dimensioning of the loop 27 of the handle 26 includes a loop diameter of 11-13 mm. With respect to the break strength for the glass handle 26, the design of the present invention provides a minimum break strength of 170 pounds. The dimensioning of the handle, including the minimum base 31 thickness of between 5.5 and 6.5 mm, achieves this strength capability. The handle is therefore not oversized, is still easily grasped with one or more fingers of a consumer, and does not create such a large handle profile that otherwise would detract from some of the aesthetic and historical dimensions associated with growlers.

There are a number of advantages to the glass container of the present invention. A growler type container incorporates a larger, wide-mouth opening in combination with a re-sealable roll-on closure. The wide mouth opening accommodates cleaning and disinfection of the container, and enhances pourability of malt type beverages. The re-sealable closure enables longer term storage of carbonated beverages at optimal carbonation levels to enhance flavor characteristics and shelf life. The integral handle is capable withstanding forces in excess of standard break strength requirements.

Claims

1. A glass container comprising:

a top portion including an opening;

a base;

a sidewall interconnecting the top portion and base;

a 38 mm roll-on closure covering said opening;

a handle mounted to said container;

wherein the sidewall has a minimum thickness of 2.5 mm and an average thickness of 4.5 mm to 5.5 mm; and

wherein said container is sealed to hold up to 3.0 v/v CO2 pressure at 145° F.

2. The glass container, as claimed in claim 1, wherein:

said container has a heel located between the sidewall and base, said heel having an average thickness of 4.0 to 5.0 mm.

3. The glass container, as claimed in claim 1, wherein:

said base includes a bearing surface formed along a peripheral portion of the base, said bearing surface having an average thickness of 6.5 to 7.5 mm.

4. The glass container, as claimed in claim 1, wherein:

said base includes a center bottom portion having an average thickness of 9.0 to 10.0 mm.

5. The glass container, as claimed in claim 1, wherein:

said base includes a mid bottom portion having an average thickness of 8.0 to 9.0 mm.

6. The glass container, as claimed in claim 1, wherein:

said container includes a shoulder disposed above an upper portion of the sidewall, said shoulder having an average thickness of 4.7 to 5.7 mm.

7. The glass container, as claimed in claim 1, wherein:

said container includes a neck disposed between a shoulder and a finish of said container, said neck having an average thickness of 5.5 to 6.5 mm.

8. The glass container, as claimed in claim 1, wherein:

said container includes a finish portion of said top portion, said finish portion having an average thickness of 3.5 to 4.5 mm.

9. The glass container, as claimed in claim 1, wherein:

said sidewall of said container has a preferred maximum to minimum glass wall thickness ratio of approximately 2:1.

10. The glass container, as claimed in claim 1, wherein:

a volume of said container is adequate to hold a 64 oz amount of a beverage.

11. The glass container, as claimed in claim 1, wherein:

a diameter of said container is up to 5.20 inches.

12. The glass container, as claimed in claim 1, wherein:

a contact diameter of said container along a bearing surface of said container is up to 4.0 inches.

13. The glass container, as claimed in claim 1, wherein:

said container has a minimum height of 11.0 inches.

14. The glass container, as claimed in claim 1, wherein:

said handle of said container has a minimum break strength of 170 lbs.

15. The glass container, as claimed in claim 1, wherein:

said container has a preferred maximum to minimum base thickness ratio of approximately 1.5:1.

16. A glass container comprising:

a top portion including an opening;

a base;

a sidewall interconnecting the top portion and base;

a 38 mm roll-on closure covering said opening;

a handle mounted to said container;

wherein said container is sealed to hold up to 3.0 v/v CO2 pressure at 145° F.; and

wherein said sidewall of said container has a preferred maximum to minimum thickness ratio of approximately 2:1.

17. The glass container, as claimed in claim 16, wherein the sidewall has a minimum thickness of 2.5 mm and an average thickness of 4.5 mm to 5.5 mm.

18. The glass container, as claimed in claim 16, wherein:

said container has a heel located between the sidewall and base, said heel having an average thickness of 4.0 to 5.0 mm.

19. The glass container, as claimed in claim 16, wherein:

said base includes a bearing surface formed along a peripheral portion of the base, said bearing surface having an average thickness of 6.5 to 7.5 mm.

20. The glass container, as claimed in claim 16, wherein:

said base includes a center bottom portion having an average thickness of 9.0 to 10.0 mm.

21. The glass container, as claimed in claim 16, wherein:

said base includes a mid bottom portion having an average thickness of 8.0 to 9.0 mm.

22. The glass container, as claimed in claim 16, wherein:

said container includes a shoulder disposed above an upper portion of the sidewall, said shoulder having an average thickness of 4.7 to 5.7 mm.

23. The glass container, as claimed in claim 16, wherein:

said container includes a neck disposed between a shoulder and a finish of said container, said neck having an average thickness of 5.5 to 6.5 mm.

24. The glass container, as claimed in claim 16, wherein:

said container includes a finish portion of said top portion, said finish portion having an average thickness of 3.5 to 4.5 mm.

25. The glass container, as claimed in claim 16, wherein:

said container has a preferred maximum to minimum base thickness ratio of approximately 1.5:1.

26. The glass container, as claimed in claim 16, wherein:

a volume of said container is adequate to hold a 64 oz amount of a beverage.

27. The glass container, as claimed in claim 16, wherein:

a diameter of said container is up to 5.20 inches.

28. The glass container, as claimed in claim 16, wherein:

a contact diameter of said container along a bearing surface of said container is up to 4.0 inches

29. The glass container, as claimed in claim 16, wherein:

said container has a minimum height of 11.0 inches.

30. The glass container, as claimed in claim 16, wherein:

said handle of said container has a minimum break strength of 170 lbs.

31. A glass container comprising:

a top portion including an opening;

a base;

a sidewall interconnecting the top portion and base;

a 38 mm roll-on closure covering said opening;

a handle mounted to said container; and

wherein said container has a glass thickness distribution including: (i) a minimum thickness of 2.5 mm; (ii) an average thickness of said sidewall of 4.5 mm to 5.5 mm; (iii) said container has a heel located between the sidewall and base, said heel having an average thickness of 4.0 to 5.0 mm; (iv) said base includes a bearing surface formed along a peripheral portion of the base, said bearing surface having an average thickness of 6.5 to 7.5 mm.

32. The glass container, as claimed in claim 31, wherein:

said base includes a center bottom portion having an average thickness of 9.0 to 10.0 mm.

33. The glass container, as claimed in claim 31, wherein:

said base includes a mid bottom portion having an average thickness of 8.0 to 9.0 mm.

34. The glass container, as claimed in claim 31, wherein:

said container includes a shoulder disposed above an upper portion of the sidewall, said shoulder having an average thickness of 4.7 to 5.7 mm.

35. The glass container, as claimed in claim 31, wherein:

said container includes a neck disposed between a shoulder and a finish of said container, said neck having an average thickness of 5.5 to 6.5 mm.

36. The glass container, as claimed in claim 31, wherein:

said container includes a finish portion of said top portion, said finish portion having an average thickness of 3.5 to 4.5 mm.