FLUID INJECTION SYSTEM AND METHOD FOR SCAVENGING OXYGEN IN A CONTAINER

Abstract

A method and system for injecting fluid into a sealed container that contains a consumable product is provided. The container is filled with a consumable product and then sealed with a closure. A fluid is injected through the closure into the container cavity after filling and sealing. The fluid increases the internal pressure of the container and scavenges oxygen in the container.

Description

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of containers. The present invention relates specifically to injection of a fluid into the container to scavenge oxygen and support the container wall.

SUMMARY OF THE INVENTION

One embodiment of the invention relates to a fluid injection method with the dual purposes of pressurizing a filled, sealed food or beverage container and scavenging oxygen in the sealed container. The method includes providing a container having an opening and cavity. The method includes filling the container cavity through the opening with a food, beverage or other consumable product. The method includes sealing the opening with a closure. The container or the closure may include a material incorporating a catalyst for the purpose of scavenging oxygen.

The method then continues by injecting a fluid through the hermetically sealed closure into the container cavity after filling and sealing. The injected fluid increases the pressure of the sealed container. The injected molecular hydrogen, when combined with the catalyst, scavenges molecular oxygen from the contents of the container via a chemical reaction.

Another embodiment relates to a fluid injection method with the dual purposes of pressurizing a filled, sealed food or beverage container permeable to molecular oxygen and scavenging oxygen in the sealed container. The method includes providing a container permeable to molecular oxygen having an opening and cavity. In another embodiment, the container may be plastic. The method includes filling the container cavity through the opening with a food, beverage or other consumable product. The method includes providing an injection molded thermoplastic closure, the closure including a top panel, a skirt extending downward away from the top panel and a thermoplastic elastomer liner coupled to a lower surface of the top panel. The method includes sealing the container opening with the closure, where the container has a first internal pressure following sealing of the container with the closure.

The method continues by inserting a nozzle through the thermoplastic elastomer liner and into the cavity of the plastic container. The method includes injecting a fluid through the nozzle into the container cavity after filling and sealing. The injected fluid may be a combination of one or more inert gases, molecular hydrogen, and may include one or more other gases. The method includes removing the nozzle from the cavity of the plastic container and from the thermoplastic elastomer liner. The thermoplastic elastomer liner self-seals forming a hermetic seal, and the container has final internal pressure greater than the initial internal pressure. The injected molecular hydrogen, when combined with the catalyst, scavenges molecular oxygen from the contents of the sealed container via a chemical reaction.

Another embodiment relates to a system for injecting fluid into a filled, sealed plastic food or beverage container to scavenge oxygen and increase the internal pressure of the container. The system includes an injection nozzle, at least one fluid source containing a fluid and at least one conduit coupling the injection nozzle to the at least one fluid source. One of the one or more fluid sources contains molecular hydrogen. The system includes at least one gauge and at least one valve coupled to the conduit to control the flow and pressure of the fluid source. The system includes an actuator coupled to the injection nozzle and configured to move the injection nozzle toward a closure sealing the food or beverage container. The injection nozzle is configured to inject the pressurizing fluid through the closure into the plastic beverage container.

Alternative embodiments relate to other features and combinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 is a fluid injection system according to an exemplary embodiment.

FIG. 2 shows a method of injecting fluid into a filled container according to an exemplary embodiment.

FIG. 3 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 4 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 5 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 6 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 7 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 8 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 9 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 10 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 11 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 12 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

FIG. 13 is a closure used with the system of FIG. 1 according to an exemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a method and a system for injecting a fluid (e.g., molecular hydrogen, a mixture of hydrogen and nitrogen, a mixture of hydrogen and an inert gas, a mixture of multiple gases with a percentage composition of hydrogen greater than atmospheric air) into a filled and sealed container are shown. The fluid can be a liquid, a gas, or a combination of liquid and gas. The injected fluid may be a combination of one or more inert gases, molecular hydrogen, and may include one or more other gases. In another embodiment, the injected fluid may be pure molecular hydrogen. In addition, closures configured to facilitate fluid injection are shown.

In general, a container (e.g., a plastic beverage bottle) is filled with a solid and/or fluid (e.g., a consumable food or beverage) and is then sealed by coupling a closure over the filling opening of the container. At least one of the container and the closure includes a catalyst (e.g., a redox catalyst). Following sealing of the container, an injection device injects a fluid through the closure into the cavity of the container. The injected fluid increases the pressure within the cavity of the container, thereby acting to support the container walls against the inwardly directed forces that the container may experience (e.g., grasp force of the end user, air pressure, forces due to stacking in storage and transportation of the filled container). The injected fluid includes at least some molecular hydrogen that, when in proximity to the redox catalyst, acts to scavenge oxygen from the contents of the container via a chemical reaction. The closure used to seal the container may include one or more elements or features configured to facilitate injection of the fluid through the closure.

In certain thin-walled containers, the containers may be originally filled with contents at atmospheric pressure, but the radial strength of the sidewall of the container is too low to prevent inward buckling of the sidewall when the container is handled by the end user or during shipping and stacking In addition, some containers are originally filled with hot or warm contents, and in such containers the pressure within the sealed container decreases as the temperature of the contents of the container cool following sealing by the closure. In these embodiments, the fluid injected by system acts to support the walls of the container from the various radially inwardly directed forces.

Many foods, beverages, and other consumable products are oxygen sensitive. The presence of molecular oxygen in containers for these food and beverage products shortens the shelf life of the product and can affect the tastes, colors, textures and other properties of the product. Oxygen may be present in the product, or it may be present in the gas filling the headspace of the container at the time the container is sealed. Oxygen may also permeate certain types of containers commonly used for packaging food and beverages, such a plastic bottles. For the purposes of this discussion, permeation of a gas means diffusion of small molecules through a polymeric matrix by migrating past individual polymer chains, and is distinct from leakage, which is transport through macroscopic or microscopic holes in a container structure. Plastic bottles and other containers can be permeated by a variety of gases other than oxygen, including hydrogen gas. The selection of certain materials for food or beverage containers can minimize the permeability rates of gases.

Regardless of whether the oxygen was sealed in the container or permeated the container after sealing, oxygen can be scavenged from sealed containers using hydrogen and a catalyst to facilitate a redox chemical reaction. For the purposes of this discussion, a catalyst is broadly defined as a molecule that facilitates a chemical reaction without being used up in the chemical reaction. The catalyst may be incorporated into the material of the container, the closure, the seal, or any other part that comes into contact with the container or its contents. The scavenging of oxygen does not remove it from the contents of the container, but instead neutralizes its effects on the contents of the container by combining it with hydrogen to create water molecules (H₂O). The amount of water created, and consequently the amount of oxygen scavenged, depends on the amount of hydrogen available to react with the oxygen present in the food or beverage container.

The system and methods described herein of pressurizing the cavity of the container following filling and sealing give the user greater precision in determining the final pressure of the container as compared to methods in which the container is pressurized prior to sealing off the container with the closure. This precision is an advantage over systems that “flush” with hydrogen gas, or pump hydrogen gas into an evacuated container before sealing. Methods that add hydrogen gas before sealing are imprecise and inefficient. These methods that add hydrogen before sealing are also less compatible with rotating continuous motion machinery used in many manufacturing applications. Similarly, it is believed that the introduction of molecular hydrogen after sealing the container leads to greater precision in controlling the amount of hydrogen introduced and consequently in calculating the amount of oxygen scavenged from the contents of the container. The various embodiments described herein combine the increase in container pressure with oxygen scavenging for greater efficiency in manufacturing.

Referring to FIG. 1, a fluid injection system 10 is shown according to an exemplary embodiment. System 10 includes an injection nozzle, shown as piercing nozzle 12. Nozzle 12 is coupled to a pressurized fluid supply; in this exemplary embodiment, the pressurized fluid supply includes two sources of fluid. One fluid source 15 is molecular hydrogen, while the other fluid source 14 contains fluid to be combined with the molecular hydrogen. Fluid source 15 is coupled to a gauge 46 and a non-return valve 33 via a conduit 11, while fluid source 14 is coupled to a gauge 48 and a non-return valve 31 via a conduit 13. Conduit 13 and conduit 11 join at a coupling device 35, from which conduit 16 emerges and enters an actuator 18. Actuator 18 is configured to move nozzle 12 toward and away from container 20 in the direction shown by arrow 22. Actuator 18 is configured to drive nozzle 12 downward with sufficient force to pierce a closure 30 on a filled and sealed container 20. In various embodiments, actuator 18 is a machine driven actuator, and in one embodiment, is a hydraulic piston and in another embodiment is a gas piston.

As shown in FIG. 1, fluid injection system 10 is configured to inject fluid into a filled and sealed container 20. In the embodiment, container 20 as shown includes a cavity 24, and contents 26 located within cavity 24. Container 20 includes a sidewall 21, a neck 28, and a closure 30 that is coupled to neck 28. The filling opening located at the upper end of neck 28 of container 20 is sealed by closure 30 after container 20 is filled with contents 26. Closure 30 includes a top wall, shown as upper panel 32 and a skirt 34 extending downward away from and substantially perpendicular to upper panel 32. Closure 30 includes at least one thread 38 formed on the inner surface of skirt 34 that engages the at least one mating thread 36 formed on the outer surface of the neck 28 of the container 20.

Closure 30 includes a liner 40 coupled to the lower surface of upper panel 32 of the closure 30. Liner 40 is formed from a compliant polymer material capable of forming a liquid and air tight seal against the upper rim of the neck 28. In various embodiments, liner 40 is formed from a thermoplastic elastomer (TPE) material, and upper panel 32 and skirt 34 are formed from a relatively rigid thermoplastic material (e.g., polypropylene, high density polyethylene, etc.).

In one embodiment, container 20 and closure 30 include materials with a low permeability to molecular hydrogen and/or molecular oxygen.

In various embodiments, a catalyst material such as a redox catalyst may be incorporated into the materials of one or more of the closure 30, liner 40, sidewall 21, or any other part of the container 20. For the desired reaction between molecular hydrogen and molecular oxygen, some embodiments may incorporate compounds including Group VIII metals as a catalyst material. These catalyst materials may be molecules or compounds incorporating palladium (Pd), platinum (Pt), or iron (Fe), but this does not preclude the use of molecules or compounds incorporating other Group VIII metals.

To inject fluid into container 20 using fluid injection system 10, filled and sealed container 20 is placed beneath nozzle 12 when nozzle 12 is in a retracted position. With container 20 in place beneath nozzle 12, actuator 18 drives nozzle 12 downward, piercing upper panel 32 and liner 40 with nozzle 12. In various embodiments, actuator 18 is a mechanically operated machine configured to move the tip of nozzle 12 a precise distance to pierce upper panel 32 and liner 40. Thus, actuator 18 is configured to move the tip of nozzle 12 at least the combined thickness of upper panel 32 and liner 40. In various embodiments, actuator 18 is configured to move the tip of nozzle 12 0.010 inches more than the combined thicknesses of the panel and liner embodiments discussed herein. In various embodiments, actuator 18 is configured to move the tip of nozzle 12 between 0.020 inches and 0.150 inches, specifically between 0.020 inches and 0.120 inches and more specifically between 0.020 inches and 0.110 inches.

As shown in FIG. 1, nozzle 12 passes through upper panel 32 and liner 40, and tip 42 of nozzle 12 is located within cavity 24 following piercing of upper panel 32 and liner 40. Following insertion, fluid flows through the nozzle 12. In this embodiment, the fluid originates from fluid source 15 and fluid source 14, through conduit 11 and conduit 13 where the respective amounts of fluid from fluid source 15 and fluid source 14 are controlled by non-return valve 33 and gauge 46 and non-return valve 31 and gauge 48. The fluid mixture emerges from coupling device 35 into conduit 16, where it then enters actuator 18 before progressing through nozzle 12 and nozzle tip 42 into the container's cavity 24.

In one embodiment, fluid supply 15 and fluid supply 14 are pressurized containers of fluids such that opening of non-return valve 33 and non-return valve 31 allow the fluids from fluid supply 15 and fluid supply 14 to flow into coupling device 35 and then into conduit 16. In another embodiment, fluid supply 15 and fluid supply 14 include high pressure pumps or compressors configured to pressurize the fluids, and in this embodiment the pumps are configured to pressurize the fluids. In various embodiments, non-return valve 33 and non-return valve 31 are electronically controlled valves configured to open following insertion of the nozzle 12 into container 20. In one such embodiment, non-return valve 33 and non-return valve 31 are solenoid actuated check valves controlled by an electronic control system (e.g., one or more computers, processing circuitry, microprocessors, etc.) that is configured to control system 10 to provide the functionality discussed herein.

In some embodiments, the amount of fluid delivered is a predetermined combination of amounts of fluids from fluid source 15 and fluid source 14. In alternate embodiments, there may be only one source of hydrogen as the fluid, or there may be more than two fluid sources, but in all embodiments the amount of fluid delivered will be predetermined. In embodiments with more than one fluid source, the amount of fluid from each fluid source is predetermined individually, so that the percentage composition of the fluid that is delivered through conduit 16 into actuator 18 and through nozzle 12 into container 20 is known for all components of the fluid mixture. Percentage composition may be determined by the calculating the respective masses of fluid components, the respective volumes of fluid components, the respective numbers of molecules or atoms of fluid components, or by any other suitable manner of calculating the composition of a fluid.

In various embodiments, the injected fluid may be a combination of molecules. In this instance, a molecule is defined as any grouping of two or more atoms bound together with chemical bonds. Such molecules may include but are not limited to compounds, where a compound is defined as having two or more atoms of different chemical elements bound together with chemical bonds. However, in some embodiments, any combination of fluids forming the injected fluid does not result in any substantial chemical reactions between the molecules before injection.

In various embodiments, the presence of the molecular hydrogen prior to delivery via the nozzle 12 provides certain benefits over previous systems in which the hydrogen was generated via a chemical reaction in the container after the container was sealed. One drawback of generating the hydrogen via chemical reaction is that the use of at least one additional active substance, such as a hydride, can prejudicially contaminate the contents of the container. In addition to unreacted reactants, the reaction producing the hydrogen may also produce byproducts, and may even lead to possible chemical reactions between the reactant and the contents of the container. The system and methods discussed herein decrease the number of chemical reactions that must occur to scavenge oxygen from the contents of the container, thereby decreasing the complexity of the task and reducing the possibility of unforeseen complications. The system and methods discussed herein also increase the precision and predictability of the oxygen scavenging, because the amount of hydrogen ultimately released in the container is more precise.

In one embodiment, system 10 is configured to deliver approximately 30 cubic centimeters (as measured at standard temperature and pressure) of fluid into container 20. In that embodiment, the approximately 30 cubic centimeters of fluid may be a gas having a percentage composition of approximately 96% nitrogen and approximately 4% hydrogen. In another such embodiment, the fluid will be 30 cubic centimeters of a gas having a percentage composition of approximately 98% nitrogen and approximately 2% hydrogen. In some embodiments, the gas may have a percentage composition of between 96% and 99.9% nitrogen, and between 4% and 0.1% hydrogen respectively.

In an alternate embodiment, the amount of fluid delivered will be approximately 5 cubic centimeters of hydrogen gas as measured at standard temperature and pressure. In this embodiment, the portion of the cavity 24 not filled by contents 26 will not be a vacuum, but will instead be filled by gas that entered the container prior to sealing 52. In some embodiments, the amount of fluid delivered may vary, but the fluid is pure hydrogen.

In an alternate embodiment, the system 10 is configured to deliver a mixture of 96% liquid nitrogen and 4% liquid hydrogen kept at a temperature below the boiling point of either fluid before delivery to the container 20. In this embodiment, the fluid is a liquid instead of a gas. In alternate embodiments, the fluid may have a percentage composition of between 96% and 99.9% nitrogen, and between 4% and 0.1% hydrogen respectively, but in this case the fluid is a liquid and not a gas.

In alternate embodiments, the fluid may have a percentage composition of nitrogen between 96% and 0%, with the remainder of the fluid comprised of hydrogen gas.

In a different set of embodiments, the fluid may be a combination of atmospheric air and pressurized hydrogen gas. In one embodiment, the fluid may be greater than or equal to 95% hydrogen, with the remainder atmospheric air. In another embodiment, the fluid may be greater than or equal to 75% hydrogen, with the remainder atmospheric air. In another embodiment, the fluid may be greater than 4% hydrogen, with the remainder atmospheric air. In another embodiment, the fluid may be greater than or equal to 0.1% hydrogen, with the remainder atmospheric air.

In all of the above embodiments, the proportion of the fluid that is hydrogen to the proportion of the fluid that is other components is varied based upon the desired results. The greater the need for oxygen scavenging, the greater the total amount of hydrogen that must be delivered into the container. The total amount of fluid delivered is also varied based upon the desired results. In various embodiments, the amount of fluid delivered varies based on the size of container 20 and on the fill level of contents 26 within container 20. The greater the needed increase in internal pressure in the container, the greater the total amount of fluid that must be delivered into the container via system 10. As discussed above, a lower fill level of contents 26 in the container 24 or the intentional decrease of the internal pressure of the container 24 prior to sealing will increase the total amount of fluid required to be delivered by system 10.

Once the predetermined amount of fluid has been delivered, nozzle 12 is retracted by actuator 18. With nozzle 12 removed, the compliant material of liner 40 self-seals forming an air-tight seal. In various embodiments, a material with the ability to self-seal is a material capable of reforming an air-tight seal without application of external energy or external initiation of the self-sealing process.

While the disclosure herein relates primarily to screw-top containers, the systems, structures and methods discussed herein could be used to inject a pressurizing and oxygen-scavenging fluid into a wide variety of sealed containers. For example, in one embodiment, structures and methods discussed herein could be used to inject a pressurizing and oxygen-scavenging fluid into a hermetically sealed container with a different closure configuration (e.g., a juice box or a soft bodied pouch containing a juice drink or other beverage). Furthermore, the container material is not limited to plastics, but may include glass, metal, or a cardboard composite material.

Referring to FIG. 2, a process 50 for injecting a fluid into a filled and sealed container is shown according to an exemplary embodiment. At step 51, a container, such as plastic container 20 discussed above, is filled with a food, beverage, medicine, or other product to be consumed by the end user. At step 52, the container 20 is sealed with the contents 26 inside. The container 20 may also contain some gas in the headspace when it is sealed. In one embodiment, the container is sealed with a closure such as closure 30 discussed above.

At step 54, the closure is sterilized prior to injecting fluid through the closure. Sterilization at step 54 can be implemented through exposure of the filled container and closure to UV light, an antiseptic chemical wash (e.g., antimicrobial fluid), flame, plasma, steam and/or hot water.

At step 56, the nozzle 12 is inserted through the closure 30 of the container 20 into the cavity 24. The nozzle 12 may be a needle, or it may be another instrument appropriate for delivering fluid in a targeted direction. The closure 30 may be specifically configured to accept the nozzle, as discussed herein.

At step 58, a pressurizing and oxygen-scavenging fluid is injected through the closure 30 as discussed above regarding FIG. 1. The fluid is injected in a pre-calculated amount based on the required final internal pressure of the container 20 and based on the amount of oxygen that must be scavenged from the contents 26 of the container 20. In various embodiments, injection 58 occurs via piercing the top panel of the closure with a needle-like piercing nozzle or via nozzle engagement with valve in closure.

At step 60, the nozzle 12 is removed from the cavity 24 of the container 20 through the closure 30.

In one embodiment, as the nozzle is removed along the same path that it entered the container, the material of the liner 40 self-seals creating a hermetic seal that allows the container 20 to maintain the final internal pressure created by the injection of the pressurizing and oxygen-scavenging fluid. This is one embodiment of step 62, the sealing of the hole created by the insertion of the nozzle 12. It should be noted that in such an embodiment, an additional step to fill the injection hole at step 62 is not needed to hermetically seal the closure 30 because the hermetic seal of the container 20 is reformed upon withdrawal of the piercing nozzle 12.

In another embodiment, the hole created through the upper panel of the closure 30 by the nozzle 12 (e.g., the injection hole) may be sealed by melting the thermoplastic material adjacent to the hole. In various embodiments, melting may be generated via use of a laser welding tool, a heat-based welding tool or an ultrasonic welding tool. In another embodiment of step 62, a melted thermoplastic or adhesive may be applied to fill or cover the injection hole. In yet another embodiment at step 62, a label or sticker may be applied over the injection hole. This label or sticker may serve purely aesthetic purposes when combined with a self-sealing material in the liner 40, or may serve a functional purpose as well by actively sealing the container 20.

In various embodiments, the system shown in FIG. 1 and the process shown in FIG. 2 is implemented via automated container processing equipment. In one specific embodiment, the system shown in FIG. 1 and the process shown in FIG. 2 is implemented via rotating continuous motion machinery.

In various embodiments, the closures of the containers used in the systems and methods discussed herein include one or more features configured to facilitate injection of fluid through the closure into the container. For example, in various embodiments, the thickness of the relatively rigid thermoplastic top panel of the closure is made to permit piercing by the piercing nozzle of the injection system, and/or the thickness of the compliant liner is made to effectively self-seal to form a hermetic seal upon withdrawal of the piercing nozzle. In other embodiments, the closure may include an injection window or area that is a thinned central portion of the closure top panel made to permit piercing by the piercing nozzle of the injection system. In other embodiments, the closure may include an injection window or area that is a central bore formed through the closure top panel filled with the compliant liner material made to permit piercing by the piercing nozzle of the injection system and to provide self-sealing. Various exemplary embodiments of such closures are shown in FIGS. 3-13.

Referring specifically to FIG. 3, a closure 80 is shown. Closure 80 includes a top panel 82 and a skirt 84 extending downward away from top panel 82. Closure 80 includes a liner 86 coupled to the lower surface of top panel 82. In various embodiments, liner 86 is formed from a compliant polymer material that self-seals (e.g., a thermoplastic elastomer material), and upper panel 82 and skirt 84 are formed from a relatively rigid thermoplastic material (e.g., polypropylene, high density polyethylene, etc.). In the embodiment shown, the thickness of top panel 82 is selected such that the piercing nozzle (e.g., piercing nozzle 12) is able to easily penetrate through top panel 82. In various embodiments, the thickness of top panel 82 is substantially the same across the diameter of closure 80 and is between 0.010 inches and 0.060 inches and more specifically is between 0.020 inches and 0.040 inches. In one embodiment, the thickness of top panel 82 is substantially the same across the diameter of closure 80 and is 0.050 inches plus or minus 0.003 inches. In another embodiment, the thickness of top panel 82 is substantially the same across the diameter of closure 80 and is 0.030 inches plus or minus 0.003 inches. In another embodiment, the thickness of top panel 82 is substantially the same across the diameter of closure 80 and is 0.010 inches plus or minus 0.003 inches

In the embodiment shown, the thickness of central liner portion 88 of liner 86 is selected to provide for hermetic self-sealing upon withdrawal of the piercing nozzle of the fluid injection system. In various embodiments, the thickness of central liner portion is between 0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050 inches, and more specifically is between 0.010 inches and 0.030 inches. In various embodiments, the thickness of central liner portion is between 0.020 inches and 0.110 inches, specifically 0.020 inches and 0.100 inches, and more specifically is between 0.020 inches and 0.080 inches. In one specific embodiment, the thickness of central liner portion is 0.010 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion is 0.020 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion is 0.040 inches plus or minus 0.003 inches.

Referring to FIG. 4, a closure 90 is shown. Closure 90 includes a top panel 92 and a skirt 94 extending downward away from top panel 92. Closure 90 is substantially the same as closure 80 except for the design of self-sealing liner 96. Liner 96 is formed from a compliant polymer material that self-seals (e.g., a thermoplastic elastomer material). Liner 96 includes a thin outer portion 98 and a thick central portion 100. Thick portion 100 of liner 96 is centrally located below the central region of top panel 92 through which the injection nozzle passes. Thick portion 100 is thickened in the region of piercing to provide improved self-sealing of liner 96.

In various embodiments, the thickness of thickened liner portion 100 is between 0.015 inches and 0.060 inches, and more specifically is between 0.020 inches and 0.050 inches. In one specific embodiment, the thickness of liner portion 100 is 0.020 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of liner portion 100 is 0.030 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of liner portion 100 is 0.040 inches plus or minus 0.003 inches. In one embodiment, the thickness of central liner portion 100 is more than twice the thickness of outer liner portion 98. In various embodiments, the thickness of thickened liner portion 100 is between 0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050 inches, and more specifically is between 0.010 inches and 0.030 inches. In various embodiments, the thickened liner portion 100 is between 0.020 inches and 0.110 inches, specifically 0.020 inches and 0.100 inches, and more specifically is between 0.020 inches and 0.080 inches.

Referring to FIG. 5, a closure 110 is shown. Closure 110 includes a top panel 112, a skirt 114 extending downward away from top panel 112, and a liner 116. Liner 116 includes a thin outer portion 118 and liner center portion 120. Closure 110 is substantially the same as closure 90 except for the thickness of top panel 112. As shown in FIG. 5, top panel 112 is thinner relative to the liner center portion 120 than the corresponding portions of closure 90. In this embodiment, top panel 112 has substantially the same thickness as liner center portion 120. In various embodiments, the thickness of top panel 112 and of liner center portion 120 are substantially the same as each other (e.g., within 0.003 inches of each other), and the thickness of both is between 0.015 inches and 0.060 inches, and more specifically is between 0.015 inches and 0.050 inches. In one specific embodiment, the thickness of both top panel 112 and liner center portion 120 is 0.020 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of both top panel 112 and liner center portion 120 is 0.030 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of both top panel 112 and liner center portion 120 is 0.010 inches plus or minus 0.003 inches.

Referring to FIG. 6, a closure 130 is shown. Closure 130 includes a top panel 132, a skirt 134 extending downward away from top panel 132, and a liner 136. Closure 130 is substantially the same as closure 80 shown in FIG. 3 except that top panel 132 includes a thinned central portion 138. Relative to the lower surface of top panel 132, thinned central portion 138 is a recess formed at the center of top panel 132. As shown, the lower surface of liner 136 is substantially planar, however a central portion 140 of liner 136 is thicker than outer portion 142, and central portion 140 fills in the recess formed by the thinned central portion 138.

In various embodiments, the thickness of thinned central portion 138 is less than one half the thickness of the outer portion of top panel 132. In such embodiments, the thickness of central portion 138 is between 0.005 inches and 0.040 inches, and more specifically is between 0.005 inches and 0.025 inches. In one embodiment, the thickness of central portion 138 is 0.020 inches plus or minus 0.003 inches. In another embodiment, the thickness of central portion 138 is 0.010 inches plus or minus 0.003 inches.

In various embodiments, the thickness of central liner portion 140 is between 0.015 inches and 0.060 inches, and more specifically is between 0.015 inches and 0.050 inches. In one specific embodiment, the thickness of central liner portion 140 is 0.020 inches plus or minus 0.003 inches. In another specific embodiment, the central liner portion 140 is 0.030 inches plus or minus 0.003 inches. In another specific embodiment, the thickness central liner portion 140 is 0.040 inches plus or minus 0.003 inches. In one embodiment, the thickness of central liner portion 140 is more than twice the thickness of outer liner portion 142. In various embodiments, the thickness of central liner portion 140 is between 0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050 inches, and more specifically is between 0.010 inches and 0.030 inches. In various embodiments, the central liner portion 140 is between 0.020 inches and 0.110 inches, specifically 0.020 inches and 0.100 inches, and more specifically is between 0.020 inches and 0.080 inches.

Referring to FIG. 7, a closure 150 is shown. Closure 150 includes a top panel 152, a skirt 154 extending downward away from top panel 152, and a liner 156. Closure 150 is substantially the same as closure 130 shown in FIG. 6 except that top panel 152 includes a central bore 158. Liner 156 includes a central portion 160 that extends through the central bore 158 such that the outer surface of central liner portion 160 is substantially coplanar with the outer surface of top panel 152. This embodiment provides a central window or passage filled with the compliant polymer material of the liner to facilitate the passage of the injection nozzle into the container.

In various embodiments, the thickness of central liner portion 160 is between 0.015 inches and 0.060 inches, and more specifically is between 0.015 inches and 0.050 inches. In one specific embodiment, the thickness of central liner portion 160 is 0.020 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion 160 is 0.030 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion 160 is 0.040 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion 160 is 0.050 inches plus or minus 0.003 inches. In one embodiment, the thickness of central liner portion 160 is more than twice the thickness of the outer liner portion and more than twice the thickness of top wall 152. In various embodiments, the thickness of central liner portion 160 is between 0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050 inches, and more specifically is between 0.010 inches and 0.030 inches. In various embodiments, the central liner portion 160 is between 0.020 inches and 0.110 inches, specifically 0.020 inches and 0.100 inches, and more specifically is between 0.020 inches and 0.080 inches.

Referring to FIG. 8, a closure 170 is shown. Closure 170 includes a top panel 172, a skirt 174 extending downward away from top panel 172, and a liner 176. Closure 170 includes a recess 178 formed in top panel 172 that is recessed below the upper most edge of shoulder 180. Closure 170 also includes a peripheral sealing rib 182. Similar to the embodiments discussed above, liner 176 acts as a self-sealing structure to reseal closure 170 following the withdrawal of the injection nozzle.

In various embodiments, the thickness of at least the center portion of liner 176 is between 0.015 inches and 0.060 inches, and more specifically is between 0.015 inches and 0.050 inches. In one specific embodiment, the thickness of liner portion 176 is 0.020 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of liner 176 is 0.030 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of liner 176 is 0.040 inches plus or minus 0.003 inches. In various embodiments, the thickness of central liner portion 176 is between 0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050 inches, and more specifically is between 0.010 inches and 0.030 inches. In various embodiments, the central liner portion 176 is between 0.020 inches and 0.110 inches, specifically 0.020 inches and 0.100 inches, and more specifically is between 0.020 inches and 0.080 inches.

Referring to FIG. 9, a closure 190 is shown. Closure 190 includes a top panel 192, a skirt 194 extending downward away from top panel 192, and a liner 196. Closure 190 includes a recess 198 formed in top panel 192 that is recessed below the upper most edge of shoulder 200. Closure 190 also includes a peripheral sealing rib 202. Similar to the embodiments discussed above, liner 196 acts as a self-sealing structure to reseal closure 190 following the withdrawal of the injection nozzle.

Similar to closure 160 shown in FIG. 7, top panel 192 includes a central bore 204. Liner 196 includes a central portion 206 that extends through the central bore 204 such that the outer surface of central liner portion 206 is substantially coplanar with the outer surface of top panel 192. This embodiment provides a central window or passage filled with the compliant polymer material of the liner to facilitate the passage of the injection nozzle into the container.

In various embodiments, the thickness of central liner portion 206 is between 0.015 inches and 0.060 inches, and more specifically is between 0.015 inches and 0.050 inches. In one specific embodiment, the thickness of central liner portion 206 is 0.020 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion 206 is 0.030 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion 206 is 0.040 inches plus or minus 0.003 inches. In another specific embodiment, the thickness of central liner portion 206 is 0.050 inches plus or minus 0.003 inches. In one embodiment, the thickness of central liner portion 206 is more than twice the thickness of the outer liner portion and more than 1.5 times the thickness of top wall 192. In various embodiments, the thickness of central liner portion 206 is between 0.010 inches and 0.110 inches, specifically 0.010 inches and 0.050 inches, and more specifically is between 0.010 inches and 0.030 inches. In various embodiments, the central liner portion 206 is between 0.020 inches and 0.110 inches, specifically 0.020 inches and 0.100 inches, and more specifically is between 0.020 inches and 0.080 inches.

As noted above, in some embodiments, injection system 10 may be configured to inject fluid into a sealed container without piercing the top wall or the liner of the closure. In some embodiments, the injection nozzle of system 10 may engage with a valve structure located in the top wall of the closure. In such embodiments, the valve structure is a one way valve that permits fluid to be injected through the valve but prevents fluid from escaping out of the container. In one embodiment, the valve in the closure is configured to only open a single time, and, in this embodiment, the valve will permanently seal closed following injection of the pressurizing fluid through the valve and into the container.

Referring to FIG. 10, closure 210 includes a top panel 212, a skirt 214 extending downward away from top panel 212 and a liner 216. Closure 210 is substantially the same as closure 80, shown in FIG. 3, except that closure 210 includes a valve, shown as flap valve 220, coupled to a through bore 222 formed in top panel 212. Valve 220 includes flaps 224 that are biased to the closed position shown FIG. 10. Upon application of sufficient pressure to the outer surface of valve 220 by the fluid injection nozzle of system 10, flaps 224 open allowing the injected fluid to flow into the container. Once filling is completed and the pressure supplied by the injection nozzle is removed, flaps 224 snap back to the closed position shown in FIG. 10 hermetically sealing closure 210.

Referring to FIG. 11, closure 230 includes a top panel 232, a skirt 234 extending downward away from top panel 232 and a liner 236. Closure 230 is substantially the same as closure 80, shown in FIG. 3, except that closure 230 includes a valve, shown as ball check valve 240, coupled to a through bore 242 formed in top panel 232. Valve 240 includes an outer collar 244 and a ball 246. Outer collar 244 couples to the inner edge of bore 242, and collar 244 includes a central channel 248. Ball 246 is located within central channel 248 and is moveable between opened and closed positions. Ball 246 is biased to the closed position shown FIG. 11. Upon application of sufficient pressure to the outer surface of valve 240 by the fluid injection nozzle of system 10, ball 246 moves downward to the open position allowing the injected fluid to flow into the container. Once filling is completed and the pressure supplied by the injection nozzle is removed, ball 246 snaps back to the closed position shown in FIG. 11, hermetically sealing closure 230.

Referring to FIG. 12, a closure 260 is shown. Closure 260 is substantially similar to closure 170 shown in FIG. 8 except closure 260 includes no liner and includes flap valve 220 coupled to a bore through the top panel of closure 260. Referring to FIG. 13, closure 270 is shown. Closure 270 is substantially similar to closure 170 shown in FIG. 8 except closure 270 includes no liner and includes ball check valve 240 coupled to a bore through the top panel of closure 260.

For the purposes of this discussion, the term coupled means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

In various embodiments, the containers discussed herein are any hermetically sealed or sealable containers. In various embodiments, the containers discussed herein are containers configured to hold consumable or edible products (e.g. a beverage, water, food, medicine, etc.). In the embodiment shown in FIG. 1, the container is a molded (e.g., blow-molded) thermoplastic beverage container configured to hermetically hold a beverage (e.g., soda, water, juice, fortified or nutrient water, tea, sports drink, energy drink, milk, milk-based beverages, etc.). In addition, the closures discussed herein are closures suitable for maintaining a hermetic seal. In particular embodiments, the closures discussed herein are injection molded thermoplastic closures.

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

Claims

1. A fluid injection method for a container that contains a consumable product comprising:

providing a container including a cavity and an opening providing access to the cavity;

providing a closure, wherein at least one of the container and the closure contains a redox catalyst;

filling the container cavity through the opening with a consumable product;

sealing the container opening with the closure; and

injecting a fluid through the closure into the container's cavity after sealing, wherein the fluid acts to pressurize the container and to scavenge oxygen from the contents of the container.

2. The method of claim 1 wherein the injected fluid has a percentage composition of hydrogen greater than 0.1%.

3. The method of claim 2 wherein the injected fluid is pure hydrogen.

4. The method of claim 2 wherein the injected fluid is a mixture of hydrogen and nitrogen.

5. The method of claim 2 wherein the fluid is a gas.

6. The method of claim 2 wherein the fluid is a liquid.

7. The method of claim 1 wherein the container is permeable to molecular oxygen.

8. The method of claim 7 wherein the container is made from blow-molded thermoplastic.

9. The method of claim 1 wherein the injection of a fluid occurs via a nozzle, the method further comprising:

piercing the closure with the nozzle prior to injection of the fluid; and

removing the nozzle from the closure after the injecting the fluid.

10. The method of claim 9 wherein piercing the closure creates a hole through the closure, and the method further comprising:

sealing the hole in the closure.

11. The method of claim 10 wherein a material of the closure is configured to self-seal, wherein the sealing of the hole is accomplished by the self-sealing of the material of the closure.

12. The method of claim 1 wherein the redox catalyst includes a compound containing a Group VIII metal or a molecule containing a Group VIII metal.

13. A fluid injection method for a sealed container that is permeable to molecular oxygen and that contains a consumable product comprising:

providing a container permeable to molecular oxygen including an opening providing access to the contents of the cavity of the container;

providing a thermoplastic closure including a top panel, a skirt extending downward away from the top panel and a thermoplastic elastomer liner coupled to a lower surface of the top panel, wherein at least one of the container, closure and liner includes a catalyst material;

filling the cavity of the container through the opening with a consumable product;

sealing the opening of the container with the closure; then inserting a nozzle through the closure and through the thermoplastic elastomer liner into the cavity of the plastic container;

injecting a fluid via the nozzle into the container's cavity after filling and sealing; and

removing the nozzle from the closure and thermoplastic elastomer liner, wherein the thermoplastic elastomer liner self-seals forming a hermetic seal, and wherein the fluid acts to pressurize the container and to bind oxygen from the contents of the container.

14. The method of claim 13 wherein the injected fluid has a percentage composition of hydrogen greater than 0.1%.

15. The method of claim 14 wherein the injected fluid is pure hydrogen.

16. The method of claim 14 wherein the injected fluid is a mixture of hydrogen and nitrogen.

17. The method of claim 13 wherein the insertion of the nozzle includes piercing at least one of the closure and the liner.

18. A system for injecting fluid into a container that contains a consumable product and that is sealed by a closure, the system comprising: wherein the injection nozzle is configured to inject the fluid through the closure into the container, and wherein the fluid is configured to change the internal pressure of the container and react to bind oxygen in the cavity of the container.

an injection nozzle;

a pressurized fluid source containing a fluid;

a conduit coupling the injection nozzle to the fluid source; and

an actuator coupled to the injection nozzle and configured to move the injection nozzle toward and away from the closure sealing the container;

19. The system of claim 18 wherein the injected fluid has a percentage composition of hydrogen greater than 0.1%.

20. The system of claim 18 wherein the injected fluid is a mixture of hydrogen and nitrogen.