Pre-Flavored Container
20230038888 · 2023-02-09
Assignee
Inventors
Cpc classification
A24F40/42
HUMAN NECESSITIES
B65B29/06
PERFORMING OPERATIONS; TRANSPORTING
B65B63/08
PERFORMING OPERATIONS; TRANSPORTING
B65B3/045
PERFORMING OPERATIONS; TRANSPORTING
B65B3/04
PERFORMING OPERATIONS; TRANSPORTING
B65D85/72
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65B3/04
PERFORMING OPERATIONS; TRANSPORTING
A24F40/42
HUMAN NECESSITIES
Abstract
A multi-stage method of filling a container for storing a liquid makes use of a pre-loading process to insert a pre-fill portion of the liquid containing at least a flavorant, and in some embodiments both a flavorant and a sweetener. This creates a container that has been predosed with flavor and other components. Such a predosed container can be stored and shipped to be filled with the remaining components, before final packaging and distribution.
Claims
1. A preloaded container comprising: a reservoir having a sidewall; and a preloaded fill portion affixed to an interior of the reservoir, the preloaded fill portion comprising a flavorant.
2. The preloaded container of claim 1 wherein the preloaded fill portion further comprises a sweetener.
3. The preloaded container of claim 2 wherein the sweetener is selected from a list comprising sugar, honey, aspartame, sucralose, saccharin, isomalt, stevia, sorbitol and other sugar alcohols.
4. The preloaded container of claim 1 further comprising a coating affixed to the preloaded fill portion.
5. The preloaded container of claim 4 wherein the coating is selected from a list comprising: a sweetener, a water soluble polymer, and a starch.
6. The preloaded container of claim 1 wherein the container is one of a bottle, a bottle preform and a can.
7. The preload container of claim 6 wherein the preloaded fill portion is affixed to the sidewall.
8. The preloaded container of claim 6 wherein the preloaded fill portion is affixed to a base of the reservoir.
9. The preloaded container of claim 6 further comprising a fill liquid selected from a list comprising water, carbonated water and alcohol.
10. The preloaded container of claim 1 wherein the container is an electronic nicotine delivery system pod.
11. The preloaded container of claim 10 further comprising an e-liquid comprising at least one of vegetable glycerine, propylene glycol, nicotine and a flavorant.
12. The preloaded container of claim 11 wherein the preloaded fill portion is one of partially soluble and fully soluble in the e-liquid.
13. The preloaded container of claim 10 wherein the preloaded fill portion is affixed to one of the sidewall and a post-wick airflow passage within the reservoir.
14. A method of filling a container for storing a liquid composition, the method comprising: preloading the container with a first portion of the liquid composition, the first portion comprising at least a flavorant; and curing the preloaded first portion within the container.
15. The method of claim 14 wherein the first portion is comprised of dry ingredients making up a subset of ingredients of the liquid composition.
16. The method of claim 15 wherein preloading the container comprises spraying the first portion of the liquid composition into the container.
17. The method of claim 14 wherein curing the preloaded first portion comprises drying the preloaded first portion.
18. The method of claim 14 further comprising filling the container with a second portion of the liquid composition and sealing the reservoir.
19. The method of claim 14 wherein the container is one of a can, a bottle and a bottle preform.
20. The method of claim 14 wherein the container is an electronic nicotine delivery system pod, and the liquid composition is an e-liquid.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] Embodiments of the present invention will now be described in further detail by way of example only with reference to the accompanying figure in which:
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[0056] In the above described figures like elements have been described with like numbers where possible.
DETAILED DESCRIPTION
[0057] In the instant description, and in the accompanying figures, reference to dimensions may be made. These dimensions are provided for the enablement of a single embodiment and should not be considered to be limiting or essential. Disclosure of numerical range should be understood to not be a reference to an absolute value unless otherwise indicated. Use of the terms about or substantively with regard to a number should be understood to be indicative of an acceptable variation of up to ±10% unless otherwise noted.
[0058] To address problems associated with cleaning and sanitizing required during the changeover of different e-liquid mixtures a discussion of the overall process of filling is beneficial.
[0059] As noted in the above discussion, both beverage containers and ENDS pods are filled with flavored liquids. These containers are filled and then sealed. With an ENDS pod, the sealing may be achieved through the insertion of an end cap. For beverage containers such as PET bottles, sealing is typically performed through the placement of a cap, such as a screw on lid. Where the container in question is a can, the can is typically provided to a distributor in two pieces, a lid and a body. The can is filled without a lid in place, and then the lid is placed atop of the open body, and is sealed to the body through the application of both heat and pressure. In all these cases, filling is done by delivering a premixed version of the liquid into the container, and sealing the container for further packaging and/or shipping. When there is changeover in the flavor of the fill liquid, the feed lines used to deliver the premixed liquid have to be cleaned to avoid cross contamination. This can be a time consuming process that reduces production capacity and unnecessarily increases the costs of the filling process.
[0060]
[0061] As a part of a novel filling process, the preform is pre-loaded with a first portion of the liquid that it will be filled with. This first portion can include a number of different components including a flavorant and optionally the sweetener. This combination can be used to line the interior of the preform, and then dried or cured. The curing process may be as simple as reducing the content of a liquid carrier such as water. This allows the pre-loaded preform to contain a dry coating of a flavorant and an optional sweetener. In some embodiments, the first portion is composed of a subset of the overall contents of the final liquid. The first portion may be largely restricted to flavorants and sweeteners. It should be understood that the sweetener may act as a binding agent allowing the remaining ingredients in the first portion to be affixed to the interior of the reservoir. If no sweetener is included, it may be necessary to add a dissolvable binding agent. In other embodiments the first portion may be defined so that it contains at least a subset of all the components of the final liquid not common across the different product lines. So, if there are three final liquids that are used to fill containers, the dry ingredients of all three liquids are identified. Components that are not common across the different final liquids are prime candidates for inclusion in the portion that will be prefilled into the preform. Sweeteners may be common across the final liquids, but may be included as part of the pre-filling portion so that the tackiness imparted by the sweetener can be used to aid in affixing the pre-filling portion to the interior of the preform. In some embodiments, the sweetener may include any one or more of sugar, honey, aspartame, sucralose, saccharin, isomalt, stevia, sorbitol, other sugar alcohols or another sweetener similar to those recited. To allow the prefilled portion to be shelf stable, a coating may be applied to prevent spoiling. Although the sweetener may provide both tackiness and a degree of shelf stability to the prefilled portion, the optional use of a coating can help ensure that the prefilled portion is protected from oxidation and other effects that could contribute to off flavors. In some embodiments, the coating may be a dissolvable polymer or other such food safe coating.
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[0063] It should be understood that in a conventional bottle filling process using PET or other polymer preforms, the preform is heated and air is blown into the preform through the neck. This heating process softens the preform, and allows for it to be inflated to the desired shape. The application of heat is done to allow the material of the preform to soften and to prevent the bottle from forming unevenly during heating. In some embodiments, to ensure a particular shape, the preform is inflated within a form that ensures that the expansion is resisted by the desired eventual shape. The application of the pre-filling portion 106 may allow for a relaxation in the evenness of the application of heat, as the pre-filling portion 106 may have heat transfer properties that aid in the even transfer of heat.
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[0065] It should be understood to those skilled in the art, that it is possible to pre-fill an inflated bottle with the pre-filled portion 106 instead of prefilling a pre-form. This may be done to avoid possible oxidation of flavor compounds during the heating and blowing process.
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[0067] In previously illustrated embodiments, prefilling portions have been illustrated as a coating on the walls of a reservoir. Although this is a feasible embodiment, it should be understood that other pre-filling techniques can be employed.
[0068] It should be understood that the two placements illustrated in
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[0070] Prior to filling, the pre-loaded container can be expanded to its full size if needed, for example by heating and inflating the pre-loaded container in step 158. Those skilled in the art will appreciate that this may be done by first inserting the pre-loaded container into a mold, so that the final shape of the container is constrained to the desired shape. It should be understood that in some embodiments, the container may be expanded to full size in step 158 in advance of pre-loading the container in step 152.
[0071] In step 160, the prefilled container is filled with the remaining portion of the fill liquid. This liquid may be heated to encourage more rapid dissolution of the pre-fill portion, but it should be understood that this is not strictly necessary, as it is likely that full dissolution can be achieved through both time and the agitation involved in shipping. In step 162, the container is sealed.
[0072] Using the containers shown in
[0073] Pods, like those shown in
[0074] The e-liquid is a mixture of a variety of different components. Some of the components are liquid, others are solids. The mixture of these components will have some of the components dissolved in the liquid components, while other solid components are held in suspension within the liquid. In some embodiments different glycerine components form the majority of the liquid portion of the e-liquid. Varying the ratio of glycerine to propylene glycol typically changes the viscosity of the e-liquid.
[0075] Although presented below in the context of use in an electronic nicotine delivery system such as an electronic cigarette (e-cig) or a vaporizer (vape) it should be understood that the scope of protection need not be limited to this space, and instead is delimited by the scope of the claims. Embodiments of the present invention are anticipated to be applicable in areas other than ENDS, including (but not limited to) other vaporizing applications. As noted above, an ENDS based e-liquid is typically composed of different components including any of vegetable glycerine, propylene glycol, nicotine and flavorings. Often, one flavorant can be substituted for another, resulting in a differently flavored e-liquid. The flavorant is often a complex mixture of different components including a sweetener such as sucralose. To avoid cross contamination between flavors, the filling system needs to be cleaned between batches. Some of the issues related to cleaning and flushing the filling systems are related to the sweetener, which when at least partially separated form the rest of the e-liquid has a tendency to become somewhat sticky. This can trap flavorants within the filling system, requiring a laborious cleaning process between filling different batches with different flavors.
[0076] In embodiments of the present invention, a new method of filling a pod is disclosed. Use of this method will also result in an interim product, in which the pod is partially filled and suitable for storage.
[0077] E-liquid is made from mixing components. In the prior art, all the components were mixed and then filled into the pod. In one embodiment, some of the constituent components of the e-liquid will be combined and inserted into the reservoir in a first fill process. In a second fill process, remaining components are filled into the pod. For example, the flavorants and sweeteners can be sprayed into the pod in the first fill process. The spraying of the flavorants can be performed to create a coating within the reservoir that can be cured and/or dried. This results in a reservoir that has at least a portion of its interior surface coated with components to an e-liquid. By drying and/or curing the coating within the reservoir, the resulting product can be a shelf stable product that can be stored for future use. It should be understood that this is a very similar process to that outlined above for filling plastic or glass bottles and metal cans.
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[0079] As seen in
[0080] By dividing the e-liquid into two portions, and separating the application of the two portions, pods can be pre-loaded with the first component and stored. This allows for the pods to be pre-loaded in larger quantities than they would be in the conventional process. This pre-loading can be done using dry components that are not common across pods (e.g. flavors) and are soluble in the liquid components of the e-liquid. During this pre-loading process, the pods may be treated with a liquid spray that can be cured or dried that will help bind the pre-loaded dry components to a portion of the reservoir. The optional drying or curing allows the pre-loaded pod to be sufficiently shelf stable that it does not need to be immediately filled with e-liquid. As noted above, shelf stability may be enhanced through the optional application of a coating to the pre-filled portion.
[0081] During the second filling process, the liquid components of the e-liquid are filled into the pod, in a process that looks similar to the existing filling process. However, it will be clear to those skilled in the art that this filling process makes use of e-liquid components that are typically common between batches, and are easier to clean from the filling system. This portion of the e-liquid may, in some embodiments, be heated to encourage dissolution of the pre-loaded components.
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[0083] At this point the pod 210 can proceed to packaging and shipping. During the packaging and shipping process, the pod 210 will be agitated and the first portion 218 will be dissolved into the second portion 220.
[0084] In each of
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[0086] In optional step 254, a drying and/or curing process is performed to affix or set the preloaded first e-liquid portion within the reservoir. It should be noted that in pods that are filled using a needle that injects e-liquid within a sealed pod, if the pod is not sealed, the step of sealing the pod (discussed below as step 262) may occur at this point. In other embodiments, with pods that are filled through a needle injecting e-liquid through a barrier such as a resilient or self healing membrane, the pre-loading may be performed through this needle, and the first portion may contain a liquid component as well.
[0087] In step 256, a pod that has been pre-loaded with a first e-liquid portion may be stored for future filling. This step may represent an end to a first part of an overall filling process, and provides an interim product that can be stored, shipped and sold.
[0088] In optional step 258, a second e-liquid portion, typically containing at least one liquid component, is pre-heated. In step 260, the pre-loaded reservoir is filled with the optionally heated second e-liquid portion. If the pod has not been previously sealed, the sealing of the pod can be performed in step 262 at this point. In some embodiments step 262 entails the insertion of the end cap into an open end of the reservoir.
[0089] It should be noted that this multi-stage filling allows for pods to be pre-dosed with a flavorant, and then later filled with the remaining portions of an e-liquid. In an ENDS environment, this allows for the preloading of pods with flavorants in one process (or sub-process). Pre-loaded reservoirs can then be filled with different second portions. In an exclusively ENDS environment, the different second portions may have different concentrations of nicotine, or may have different ratios of vegetable glycerine (VG) to propylene glycol (PG). This allows flavors to be filled within the pods, and for the determination of the remaining characteristics (e.g. nicotine concentration, PG-VG ratios, etc.) to be varied according to needs.
[0090] In environments where pods are created for more than just ENDS, it would be possible to create a process where the flavoring of a pod is performed in a first process, and as a function of the second process, different e-liquids are created. In one embodiment, a first set of pre-loaded pods could be filled with e-liquids that provide nicotine, while a second set of pre-loaded pods could be filled with e-liquids containing another compound such as caffeine, and a third set of pre-loaded pods could be filled with e-liquids containing neither nicotine nor caffeine. A conventional e-liquid may use the liquid base to dissolve some compounds while other components are held in suspension. As such, it should be understood that the preloaded pre-fill may not necessarily need to be fully soluble, so long as it is partially or substantially dissolved and the remaining components can be held in suspension.
[0091] This method allows for the dosing of flavorants to be performed in a single location, and have the containers filled at a plurality of different locations. This may allow for a better control of the flavorant dosing in industries such as the beverage sector. Furthermore, in a beverage production context, it may allow for a manufacturer to use a pre-loading of flavorant in a first process, and then in separate filling processes different liquid portions could be later added, allowing for the production of alcoholic beverages and non-alcoholic counterparts with the same flavoring.
[0092] During a conventional filling process different flavours of product are created on different production lines, or on the same production line at different times. The creation of a multi-flavored package of containers becomes a complex process in which filled containers of different flavors need to be warehoused and then combined into a single package. This increases the amount of warehousing required, and increases the complexity of the product line. Using pre-loaded containers, different flavours can be stored separately, but require no more storage space than unfilled containers in the previous example. The flavours can be mixed and matched to create different mixes of the flavor as needed, which may provide flexibility in production. To facilitate this, containers may be labelled during the first stage filling process to allow them to be properly identified later. This labelling may involve printing a computer readable token on the container. In the example of a beverage can, this may include printing a flavor code on the bottom of the can, it may include printing a flavor code onto a top edge of the can body which would be obscured by the placement of the lid after the filling process is complete, or it could entail different human readable labels or paints on the cans which can be read by computer vision systems. In other embodiments, each container can have a serial number printed on it before filling. This number can be read during the pre-filling stage and associated with a flavor in a database accessible in the second stage filling process. It should be understood that any number of different known labelling techniques can be used without departing from the bounds of the invention.
[0093] It should also be understood that in the embodiments of
[0094] In the instant description, and in the accompanying figures, reference to dimensions may be made. These dimensions are provided for the enablement of a single embodiment and should not be considered to be limiting or essential. The sizes and dimensions provided in the drawings are provided for exemplary purposes and should not be considered limiting of the scope of the invention, which is defined solely in the claims.