Nitrogen flushing of aluminum packaging to preserve nucleating effect in a nucleating can after filling and pasteurization

Abstract

In a method of filling a containment space (42) of a beverage container (1), a container (1) having a containment space (42) is provided. The container (1) has a product side and a public side. The product side has a nucleating surface thereon. A nitrogen stream under pressure is introduced into the containment space (42) to flush the containment space (42). The containment space (42) is filled with a beverage (200) subsequent to the introducing the nitrogen stream step.

Description

Attorney Docket No. 6365.152516PCTC1 PATENT1NITROGEN FLUSHING OF ALUMINUM PACKAGING TO PRESERVE NUCLEATING EFFECT IN A NUCLEATING CAN AFTER FILLING AND PASTEURIZATIONDESCRIPTIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to PCT / US2024 / 041619, filed on August 9, 2024, the contents of which is hereby incorporated by reference as if fully set forth herein.FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] N / ATECHNICAL FIELD

[0003] The invention relates to packaging of beverages; more particularly, the invention relates to elements for nucleation and foam generation in beverages stored in containers.BACKGROUND OF THE INVENTION

[0004] It is frequently desirable to produce a foamy head on a beverage prior to consumption. Typically, this foamy head is produced when the beverage is poured from a container into a glass. The foamy head is produced by release of gas, such as carbon dioxide and / or nitrogen dissolved under pressure in the beverage. The pouring action causes an initiation of gas release which produces a foaming effect to produce the foamy head.

[0005] It is often required to cause a foamy head to be formed upon an opening of a container, for example, where the contents are to be consumed directly from the container. These containers feature a means to initiate the foaming action as soon as the container is opened and pressure in the container is released. This means typically takes the form of a secondary compartment in the container containing gas under pressure. The gas is released through a nozzle in the secondary compartment, on opening of the main container, to cause “seeding” of gas release from the container contents.

[0006] The beverage may be beer or any other beverage where it is desirable to produce a foamy head. The gas dissolved in the beverage may be nitrogen as well as carbon dioxide or nitrous oxide, and the gas stored in the secondary compartment may be carbon dioxide or nitrogen.

[0007] More recently, it has been proposed that such foamy heads can be produced by beverage contact with a nucleating surface. This means for producing a foamy head takesAttorney Docket No. 6365.152516PCTC12 advantage of the so-called Mentos eruption whereby contact of a beverage with a nucleating surface causes dissolved CO2 to rapidly and uncontrollably come out of solution.

[0008] Currently, known beverage container filling processes using a nucleating coating do not differ from legacy filling processes. In a typical filling processes, CO2 air is used to purge a container prior to filling with a beverage.

[0009] Since pasteurization is commonly used in the field of beer manufacturing, it has been noted that high temperatures during this process diminishes the effect of nucleation. It is believed that CO2 gas bubbles from the beer are absorbed into the liquid during high temperature pasteurization due to the high solubility of CO2 into beer.

[0010] The present invention is provided to solve the problems discussed above and other problems, and to provide advantages and aspects not provided by prior means for producing a foamy head of this type. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.SUMMARY OF THE INVENTION

[0011] An aspect of the present disclosure is directed to a method of filling a containment space of a beverage container comprising the steps of: providing a container comprising a containment space, the container having a product side and a public side, the product side having a nucleating surface thereon; introducing a nitrogen stream under pressure into the containment space to flush the containment space; and filling the containment space with a beverage subsequent to the introducing the nitrogen stream step.

[0012] This aspect of the disclosure may include one or more of the following features, alone or in any reasonable combination. The introducing the nitrogen stream step may flush a contents from the containment space prior to the filling the containment space. The nitrogen stream may be a gas. The nitrogen stream may be greater than 78% nitrogen. The nitrogen stream may be between 80% and 100% nitrogen. The nitrogen stream may be substantially 100% nitrogen. The method may further comprise the step of enclosing the beverage within the containment space by forming a substantially fluid-tight seal over an open end of the container to substantially fluidically seal the beverage in the containment space. The method may further comprise the steps of heating the beverage to a pasteurization temperature, and holding the beverage at the pasteurization temperature for a predeterminedAttorney Docket No. 6365.152516PCTC13 duration of time. The nucleating surface may comprise a plurality of nucleation sites. The nucleation sites may be arranged in clusters, each cluster comprising a subset of the plurality of nucleation sites. Each subset may comprise at least 5 nucleation sites. A density of the clusters may be at least 31 clusters per mm2. Each cluster may be separated from an adjacent cluster by an area free of nucleation sites, wherein a total area free of nucleation sites is less than a total area of the clusters. The product side of the containment space may comprise a primary coating, wherein the primary coating comprises the nucleating surface, and the area free of nucleation sites is formed from the primary coating. Each of the plurality of nucleation sites may be formed by a differential thickness in the primary coating. The plurality of nucleation sites comprise at least one of a plurality of bumps and a plurality of craters. The primary coating comprises inclusions, wherein the inclusions create the plurality of nucleation sites. The inclusions may comprise a plurality of solid particles. The plurality of solid particles may comprise at least one of a wax, spherical in shape, a raised conic shape, and a conic-shape with a divot. The nucleating surface may be formed by deforming a container wall of the container. The container wall may be deformed by one or more of a laser etching, a chemical reaction, a mechanical embossing, and a mechanical debossing. The primary coating may comprise a polyolefin dispersion. The polyolefin dispersion may form random swirls causing a differential thickness in the primary coating forming the nucleating surface. The differential thickness may be caused by a solvent in the primary coating, wherein the solvent transforms from a liquid to a gas during curing of the primary coating to produce the at least one of the plurality of bumps or the plurality of craters. Each of the plurality of nucleation sites may be formed by at least one of cracks in the primary coating and crazing in the primary coating. The primary coating may comprise deformations caused by one or more of a laser etching, a chemical reaction, a mechanical embossing, and a mechanical debossing, wherein the deformations form each of the plurality of nucleation sites. A primary coating may be deposited on the product side of the containment space and a secondary coating may be located on an otherwise exposed surface of the primary coating opposite a surface of the primary coating in contact with the container wall, wherein the secondary coating comprises the plurality of nucleation sites. The secondary coating may comprise inclusions, wherein the inclusions create the plurality of nucleation sites. The inclusions may comprise a plurality of solid particles. The inclusions may be suspended in a binder. The secondary coating may comprise a decal. The secondary coating nay be a reticulating coating. The secondary coating may comprise deformations caused by one or more of a laser etching, a chemical reaction, a mechanical embossing, and a mechanicalAttorney Docket No. 6365.152516PCTC14 debossing, wherein the deformations form each of the plurality of nucleation sites. Contact between the beverage and the nucleating surface may cause a controlled foam to develop on a top surface of the beverage when a seal is removed. The foam may be a micro-foam. The seal may be provided by a lid having threads attached to a container body. The seal may be provided by a lid seamed to a container body. The lid may be produced from a metallic material. The metallic material may be an aluminum alloy. A headspace may be located in the containment space between a top surface of the beverage and a product side of a lid, wherein the headspace has a volume that is equal to or greater than 9.4% of a total volume of the containment space. The headspace may comprise undissolved nitrogen. The method may further comprise the step of depositing a dose of liquid nitrogen on the beverage within the containment space prior to substantially fluidically sealing the beverage in the containment space. A fluid may be dissolved in the beverage within the containment space. The container may be a metallic drinking cup. The container may be a two-piece beverage container. A pasteurization temperature may be between 140° F to 180° F (60° C to 82° C). A pasteurization temperature may be between 140° F to 162° F (60° C to 72° C). The predetermined duration of time of a pasteurization process may be between 15 seconds and 30 minutes. The beverage may be beer. The containment space may be substantially empty prior to the introducing a nitrogen stream step. A pressure of the nitrogen stream may be delivered at between 50 psi to 100 psi. Prior to the introducing the nitrogen stream step, the nucleating surface may comprise a plurality of nucleation sites wherein at least one nucleation site in the plurality of nucleation sites comprises a volume of air within a crater, wherein the introducing the nitrogen stream step flushes the volume of air from the crater and replaces the volume of air with a volume of nitrogen.

[0013] Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

[0015] FIG. 1 is a side view of a two-piece beverage container;

[0016] FIG. 2 is a top of a two-piece beverage container;

[0017] FIG. 3 is partial cross-sectional view of a two-piece beverage container;

[0018] FIG. 4 is a partial cross-sectional view of a two-piece beverage container with a seal removed to cause a controlled foamy head to form on a top surface of a beverage;Attorney Docket No. 6365.152516PCTC15

[0019] FIG. 5 is a side view of a two-piece beverage container having a threaded lid;

[0020] FIG. 6 is a cross-sectional view of a two-piece beverage container having a threaded lid;

[0021] FIG. 7 is cross-sectional view of a two-piece beverage container with a seal removed to cause a controlled foamy head to form on a top surface of a beverage;

[0022] FIG. 8 is an elevational view of a cup, preferably produce from aluminum or an aluminum alloy;

[0023] FIG. 9 is a cross-sectional view of the cup of FIG. 5 with a controlled foamy head on a top surface of a beverage;

[0024] FIG. 10 is a cross-sectional side view of a segment of a container containment space having a product side with a nucleating surface;

[0025] FIG. 11 is a cross-sectional side view of a segment of a container containment space having a product side with a primary coating having a nucleating surface;

[0026] FIG. 12 is a cross-sectional side view of a segment of a container containment space having a product side with a primary coating having a nucleating surface;

[0027] FIG. 13 is a cross-sectional side view of a segment of a container containment space having a product side with a primary coating having a nucleating surface;

[0028] FIG. 14 is a cross-sectional side view of a segment of a container containment space having a product side with a primary coating and a secondary coating having a nucleating surface;

[0029] FIG. 15 is a cross-sectional side view of a segment of a container containment space having a product side with a primary coating and a secondary coating having a nucleating surface;

[0030] FIG. 16 is a cross-sectional side view of a segment of a container containment space having a product side with a primary coating and a secondary coating having a nucleating surface;

[0031] FIG. 17 is a cross-sectional side view of a segment of a container containment space having a product side with a primary coating and a secondary coating having a nucleating surface;

[0032] FIG. 18 is a top view of a lid having a pour opening defined by a plurality of turbulence inducing small apertures and a nucleating surface region;

[0033] FIG. 19 is a side view of a conic-shaped nucleation site having a rounded bump;

[0034] FIG. 20 is a side view of a conic-shaped nucleation site having a crater;Attorney Docket No. 6365.152516PCTC16

[0035] FIG. 21 is a micrograph of a product side of a container body sidewall with a coating deposited thereon at 100X;

[0036] FIG. 22 is a micrograph of a product side of an upper portion of a container body sidewall with a coating deposited thereon at 300X;

[0037] FIG. 23 is a micrograph of a product side of a mid-portion of a container body sidewall with a coating deposited thereon at 300X;

[0038] FIG. 24 is a micrograph of a product side of a lower portion of a container body sidewall with a coating deposited thereon at 300X;

[0039] FIG. 25 is a flowchart of a method for filling the containers of the present disclosure;

[0040] FIG. 26 is a schematic of nucleation site prior to an introducing of nitrogen gas stream under pressure to a containment space; and

[0041] FIG. 27 is a schematic of a nucleation site subsequent to an introduction of nitrogen gas stream under pressure to a containment space, wherein introducing the nitrogen gas stream under pressure flushes a volume of air from the nucleation site and replaces the volume of air with a volume of nitrogen gas.DETAILED DESCRIPTION

[0042] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

[0043] The present disclosure is aimed at providing or developing a foam or foamy head on a beverage, similar to the commonly provided secondary compartment or widget technology but without the use of plastic or complicated assembly methods. It is further desirable to adapt such foaming to other containers, such as bottles and cups where widget technology is not feasible. It is still further desirable to extend such foam experience to draft coffee that is currently poured into cups. Nucleation sites extend the duration that foam is generated during the drinking experience.

[0044] As used herein, the terms “foam” and “foamy head” refer to a light mass of bubbles of a liquid formed in or on a surface of a beverage. A preferred foam or foamy head is a micro-foam. A micro-foam or micro-bubbles is / are a term known in the art of beverage making to indicate a foam comprising bubbles that are small enough that they cannot beAttorney Docket No. 6365.152516PCTC17 individually seen by a consumer at arm’s length, preferably microscopic. The bubbles forming the micro-foam appear as a uniform, homogenous structure. In contrast, carbonation bubbles in soda are on the opposite end of the scale. They are individually identifiable at arm’s length, and due to the size of the bubble spheres, the surface of the foam would be lumpy. In the middle are low carbonation or mixed gas bubbles. They are individually identifiable, but are small enough that their spheres do not interrupt the general flatness of the top of the foam. As used herein, the terms “micro-foam” and “micro-bubbles” are species of a foam or foamy head genus.

[0045] The present disclosure includes a nucleating surface within a beverage-filled container. The nucleating surfaces described herein have a plurality of non-smooth nucleation sites, typically bumps (protrusions) or craters (recesses). These nucleation sites increase a total surface area of a containment space wall. The nucleation sites basically act as a surfactant, meaning the nucleation sites reduce the surface tension of the beverage. When the beverage contacts the nucleation sites, gas in solution in the beverage is released such that a controlled foam develops on a top surface of the beverage.

[0046] The present disclosure includes flushing a nucleating surface of a container prior to introducing a beverage into the container. During the filling process, nitrogen gas is used to flush out all other gasses from the internal void area of the empty nucleating coated container before the container is filled. In use, a “gas seed” that propagates a nucleating when a container is opened becomes nitrogen instead of CO2. Nitrogen, being less soluble than CO2, is better able to survive and remain intact during high temperature pasteurization. This results in a better foaming effect after pasteurization. One purpose of the nitrogen flush is to preserve nucleation when the nucleation and foam generation is desired.

[0047] The present disclosure includes treating the beverage-filled container with liquid nitrogen immediately prior to sealing the beverage-filled container.

[0048] The beverage may be a non-carbonated beverage. Liquid nitrogen is often added to non-carbonated beverage-filled containers immediately prior to a sealing of the noncarbonated beverage-filled container. As the liquid nitrogen changes to gas, the container becomes pressurized to have the necessary rigidity to resist damage in shipping / handling. For example, liquid nitrogen can be administered or added to the beverage after filling and immediately before seaming the lid. Because the nitrogen is not immediately dissolved in the product during filling, the non-carbonated beverage in the beverage-filled container does not have dissolved gas to react to nucleation sites. However, once the beverage-filled container is sealed with a lid, end, cap, or other sealing member, and some nitrogen dissolves intoAttorney Docket No. 6365.152516PCTC18 solution, the non-carbonated beverage product is capable of nucleating and creating foam. This is a condition that a consumer would experience when the beverage-filled container is unsealed.

[0049] Principles disclosed herein can be applied to beverage containers, such as filled and sealed beverage containers, for example, two-piece metallic beverage cans and metal, glass, and plastic bottles, as well as open-ended cups produced from glass, plastic, or metal. These containers can be manufactured to have a product side that promotes nucleation, such as a nucleating surface comprising a plurality of nucleation sites. Such surfaces commonly cause carbonated beverages, for example beer and soft drinks, to have excessive foaming during and / or after filling and before container sealing in the case of sealed beverage container.

[0050] Still, non-carbonated, and minimally carbonated beverages would not foam excessively after filling due to the lack of gas that is dissolved in solution (the beverage). The beverage subsequently receives a dose of liquid nitrogen after filling but before sealing. Most such beverages receive some dose of liquid nitrogen to increase package pressure to prepare for distribution. Because the drop of liquid nitrogen floats on a beverage surface, the beverage does not foam excessively prior to sealing or closing the beverage-filled container. After sealing, some gas migrates into solution according to Henry’s Law. Upon opening, the dissolved nitrogen will nucleate against a special product side and create a high quality foam, preferably a micro-foam as defined above, to enhance the consumer experience.

[0051] Key features of the present disclosure include, but are not limited to, nucleating surface coatings and nucleating surfaces and manufacturing methods, methods of filling where foaming does not occur after filling and before seaming, but foam is generated at time of beverage opening, foaming that continues while the beverage is slowly being consumed, providing pour openings comprising a plurality of small apertures and / or closures comprising a plurality of small apertures to promote turbulence with relatively low nitrogenated product pressures and heat sealable film / foil closures, where secondary compartments, i.e., widgets, are only relevant for sealed containers, the principles of the present disclosure can be applied to cans, bottles, and cups.

[0052] It is imperative that too much foam does not form at the filler when a beverage is introduced into an empty container. If too much foam is generated at the filler, then it is also likely too much foam will foam when the consumer opens the container. Beer inherently has CO2 as a biproduct of brewing. And at natural levels, it would likely be too much gas and excessive foaming would occur at filling / at consuming.Attorney Docket No. 6365.152516PCTC19

[0053] In some cases, to enhance foaming, CO2 can be added to a beverage formulation in addition to nitrogen added to the headspace. In which case, 1.0 gas volume of CO2 can be added in the beverage (in solution prior to filling), and then the container can be pressurized with nitrogen.

[0054] For reference, soda is typically carbonated to 3 to 4 gas volumes of CO2. preferably 3 to 3.2 gas volumes. Beer is often 1.8 to 2.4 gas volumes of CO2, more broadly 1.0 v / v up to 2.85 v / v. 1.0 gas volume of CO2 produces a minimal, if any, bubbling effect. Nitrogen is not very soluble, so added CO2, which is very soluble, can enhance the foaming experience.

[0055] One aspect of this disclosure centers around a nucleating surface on a container filled with a beverage that may have some dissolved gas (but not so much that it would foam extremely after filling) and then adding additional gas via super cooled liquified gas. In this way, the foaming is greater at the consumer, and less at filling / before seaming.

[0056] According to an aspect of the disclosure, although a beverage is immediately in contact with a nucleating surface prior to sealing the beverage container package, the beverage is not sufficiently gasified for significant nucleation to occur until after the package is sealed. In this way, the dissolved gas in the beverage does not exist until after the package is sealed. This is accomplished by adding liquified gas to the beverage prior to sealing. For a given beverage (with varying abilities to generate bubbles or foam), if that is not enough gas to achieve the desired consumer nucleation effect, a low level of dissolved gas, for example, CO2, can be added to the beverage prior to filling. The dissolved gas in the product prior to filling into a can / bottle will preferably be low enough to avoid gushing / product loss before the seamer / capper. Otherwise, to control gushing or uncontrolled foaming prior to sealing the beverage in the container.

[0057] Other principles of the present disclosure include forming the nucleating surface after sealing and removing a protective cover on the nucleating surface, which protective cover prevents beverage contact with the nucleating surface, after the beverage is sealed within the container.

[0058] Referring to FIG. 1-9, well-known beverage containers are illustrated. As used herein, the terms “container” and “beverage container’ are used interchangeably and are simply intended to broadly refer to any vessel configured or intended to hold a liquid beverage. The concepts of the present disclosure can be applied to any of the particular contained shown and described, as well as other containers that hold liquid beverages.Attorney Docket No. 6365.152516PCTC110

[0059] Referring to FIGS, 1-4, a two-piece beverage container 1 is illustrated. This type of container 1 is typically produced from a metallic material, generally aluminum and alloys thereof. Two-piece beverage containers comprise a can end or lid 10 attached to a container or can body 40.

[0060] The lid 10 has a center panel 12 separated from a seaming curl 14 by a circumferential wall 15 extending downwardly from the seaming curl 14 to a strengthening segment 16 which is joined to the center panel 12.

[0061] The lid 10 can be joined to a container body 40 by the seaming curl 14 which is joined to a mating curl of the container body 40. The seaming curl 14 of the lid 10 is integral with the center panel 12 by the circumferential wall 15 and the strengthening segment 16, typically either a generally U-shaped countersink or a fold, which is joined to a peripheral edge of the center panel 12, which defines an outer perimeter of the center panel 12, often through an additional strengthening feature such as a circumferential step or other circumferential wall.

[0062] The circumferential seaming curl 14 defines an outer perimeter of the beverage lid 10. It is generally centered about a longitudinal or vertical axis 50, sometimes located at a center of a rivet.

[0063] The circumferential wall 15 extends downwardly from a radially inner portion of the seaming curl 14.

[0064] The circumferential strengthening segment 16 is joined to a lower segment of the circumferential wall 15 and extends circumferentially about the center panel 12.

[0065] The center panel 12 has a means for opening the end 10. The means for opening the lid 10 may include a displaceable foil closure member or as shown in FIG. 1, a tear panel 22 defined by a curvilinear frangible score 24 and a non-frangible hinge segment 26 which extends between terminal ends of the frangible score 24. Accordingly, the hinge segment 26 is defined by a generally straight line between a first end and a second end of the frangible score 24.

[0066] The tear panel 22 of the center panel 12 may be opened, that is the frangible score 24 may be severed and the tear panel 22 displaced at an angular orientation relative to the remaining portion of the center panel 12, while the tear panel 22 remains hingedly connected to the center panel 12 through the hinge segment 26. In this opening operation, the tear panel 22 is displaced at an angular deflection, as it is opened by being displaced away from the plane of the panel 12. This deflection of the tear panel 22 creates a pour opening 27 throughAttorney Docket No. 6365.152516PCTC111 which the contents (solid, liquid, or gas) the container can exit a containment space 42 of the container 1. This opening sequence will often plastically deform the material of the lid 10.

[0067] The lid 10 has a tab 28 secured to the center panel 12 adjacent the tear panel 22 by a rivet 38 which passes through an aperture in a tongue area of the tab 28. The rivet 38 is formed in the typical or customary manner well known in the art of lid manufacture.

[0068] The container body 40 is formed from a unibody wall comprising a lower portion and an upper portion. When seamed to a lid 10, a product side 34 of the upper and lower portions of the container body 40 together with a product side 34 of the lid 10 create a containment space 42 for holding a liquid beverage. A headspace 59 is formed between a top surface 202 of the beverage 200 in the containment space 42 and the lid. The lower portion includes an enclosed bottom 56 and a cylindrical sidewall 60 extending upwardly from the enclosed bottom 56 portion.

[0069] The bottom 56 has a dome-shaped center panel surround by a generally a circumferential annular support. An outer wall extends radially outwardly and upwardly relative to the annular support and joins the bottom 56 with the lowermost portion of the cylindrical sidewall 60.

[0070] The cylindrical sidewall 60 is centered about the longitudinal axis 50. The sidewall 60 is smooth and flat. However, one of ordinary skill in the art would appreciate that any one of a number of forming techniques could be employed to impart a shape and / or texture to the sidewall 60 as will be described below.

[0071] The upper portion includes a circumferential shoulder 64 portion. The shoulder 64 has a convexly curved appearance when viewed from the public side 32 of the container 1. The shoulder 64 has a lowermost point integral with an uppermost portion of the cylindrical sidewall 60. The transition point between the sidewall 60 and shoulder 64 is at a point where the container body 40 begins to curve radially inwardly. Stated another way, the diameter of the container body 40 begins to decrease at the point where the shoulder 64 begins and the sidewall 60 ends.

[0072] The upper portion further includes a neck 68. The neck 68 has a lowermost portion integral with an uppermost portion of the shoulder 64. The neck 68 is preferentially substantially flat, i.e., primarily free of an arc-shape design, although it may have some discontinuity formed during production. A diameter of the container body 40 in the neck 68 is relatively constant.

[0073] The upper portion also includes a radially outwardly extending flange located above the neck 68. This flange is integral with an uppermost portion of the neck 68. TheAttorney Docket No. 6365.152516PCTC112 flange has a convex appearance when viewed from a vantage point above the container body 40, i.e., looking down at the open end of the container body 40. The flange cooperates with the curl 14 of the lid 10 during a seaming operation to enclose the containment space 42 with a substantially fluid-tight seal. Here, the term “substantially” is intended to encompass a seal which prevent a gas from completely escaping the containment space 42 for at least one month.

[0074] Referring to FIGS. 5-7, the container 1 is in the form of a bottle. The bottle can be produced from a metallic material, glass, or plastic. Here, the container 1 has a threaded open end 140. The structure of the container body 40 is similar to the container body previously described in reference to FIGS. 1-4.

[0075] Referring to FIGS. 8-9, the container 1 is in the form of a cup. The cup can be produced from a metallic material, glass, or plastic. Here, the container l is a one-piece (unibody) drinking cup. The drinking cup contemplated by the present disclosure may be produced from aluminum or an aluminum alloy.

[0076] Each of the containers 1 described above has a containment space 42. According to FIGS. 1-7, the containment spaces 42 are sealed then opened to consume the beverage. According to FIGS. 8 and 9, the containment space 42 is open. Each of these containers 1 comprises a nucleating surface 100 located within their respective containment spaces 42. The nucleating surfaces 100 have a plurality of nucleation sites 104 which serve as locations to generate bubbles from which a foamy head 204 develops on the beverage within the containment space 42, preferably a micro-foam.

[0077] As shown, for example, in FIG. 21, the nucleation sites 104 can be arranged in clusters or galaxies 144 distributed on the product side 34 of a wall of the containment space 42. Each cluster or galaxy 144 comprises a subset of the plurality of nucleation sites 104, preferably at least 5 nucleation sites 104. A density of the clusters or galaxies 144 is at least 31 clusters 144 per mm2. Each cluster or galaxy 144 is separated from an adjacent cluster or galaxy 144 by an area of the product side 34 of the wall of the containment space 42 free of nucleation sites 104, wherein a total area of the product side 34 of the wall of the containment space 42 free of nucleation sites 104 is less than a total area of the cluster or galaxies 144 on the product side 34 of the wall of the containment space 42. The wall can be the product side 34 of the lid 10, container body sidewall 60, and / or the bottom 56 of the container 1.

[0078] FIGS. 10-17 each show a magnified view of the product side 34 of the containment space 42 having a nucleating surface 100 comprising a plurality of nucleation sites 104 thereon.Attorney Docket No. 6365.152516PCTC113

[0079] Referring to FIG. 10, the containment space 42 of the container 1 may have a nucleating surface 100 formed from a wall from which the containment space 42 is formed. Here, the nucleating surface 100 has nucleation sites 104. These nucleation sites 104 can be created by a deformation treatment applied to material of the container 1. Here, the nucleation sites 104 can be applied by one or more of laser etching, chemical reaction, mechanical embossing, and mechanical debossing on one or more of the public side 32 and the product side 34 of the containment space 42.

[0080] According to FIGS. 11-13, the product side 34 of the containment space 42 of the container 1 has a primary coating 108 deposited thereon. Application of the primary coating 108 on beverage containers 1 is well-known in the art of beverage packaging and is used to protect against direct contact of the beverage 200 within the containment space 42 with the bare material surface of the material used to produce the container 1. Here, the nucleating surface 100 can be formed by the primary coating 108 and / or through additives to the primary coating 108.

[0081] For example, the nucleation sites 104 can be formed by thickness differentials on the primary coating 108. The thickness differential can be caused by a plurality of inclusions 112. (See FIG. 11). The inclusions 112 are solid particles held in place by the primary coating 108. These inclusions may be embedded in the primary coating 108 or mixed within the primary coating 108.

[0082] In one embodiment, a product side 34 of a containment space 42 of a container 1 has a coating 108 applied thereto. The coating 108 is cured to at least a semi-solid state. The coating 108 forms a nucleating surface 100 comprising inclusions 112. The inclusions 112 are solid particles causing raised coating features. For example, the inclusions 112 can comprise or be formed by a wax material, wherein the inclusions 112 cause thickness differential features that are on the order of 0.001 inches from a base thickness of the coating 108. These inclusions 112 are generally round in shape and may include raised conics 118 (see FIG. 19) or conics with center divots or craters 116 (see FIG. 20).

[0083] In one embodiment, the product side 34 of the containment space 42 of the container 1 has the primary coating 108 applied thereto. The coating 108 is cured to at least a semi-solid state. The coating 108 is preferably a polyolefin dispersion having random swirls 114, wherein the swirls 114 have or cause thickness differentials variations in the coating 108. (See FIG. 12). This non-uniform coating surface thickness provides nucleation sites 104.Attorney Docket No. 6365.152516PCTC114

[0084] In one embodiment, the primary coating 108 located on the product side 34 of the containment space 42 of the container 1 can be etched, preferably by a laser, to form nucleation sites 104 on the primary coating 108. Etching methods may include chemical etching, mechanical etching, for example, using brushes, or lasers. Alternatively, a base material used to form the container 1 can be etched prior to application of the primary 108 coating. In the case of a laser, only portions of a coating thickness are removed so that metal is not exposed after coating to alleviate corrosion concerns.

[0085] In one embodiment, nucleation sites 104 are created on the primary coating 108 when exposed to an energy from a source of energy. The source of energy may be different electromagnetic wavelengths ranging from visible light to gamma rays to e-beam or heat (as in a temperature increase). The energy can be applied to a filled and sealed container.

[0086] According to FIG. 13, thickness differentials which form nucleation sites 104 are created by craters 116 in the primary coating 108.

[0087] In one embodiment, the craters 116 can be caused by a solvent in the primary coating 108. Thus, the nucleating surface 104 comprises craters . The craters 116 are formed by solvent blisters. The craters 116 are formed by a coating 108 on the product side 34 of the containment space 42 of the container 1. The coating 108 is cured in a hot oven environment. Heat penetrates and cures the coating 108 moving, perhaps traveling radially outwardly, from an exterior or exposed surface of the coating 108 towards material of the container 1. The heat causes a skin on the exposed surface of the coating 108 to quickly or flash cure such that a skin is formed over uncured coating 108. Additional heat or additional curing duration of the internal coating radially outwardly from the exposed surface skin nearer to the material of the container 1 limits the ability of solvent in the coating 108 to evaporate such that the solvent is trapped under the skin. As the liquid solvent turns to gas, it inflates the “skin” causing a bubble or blister. Many of the bubbles or blisters break leaving a crater 116 geometry surface within the containment space 42 to form the nucleating surface 100 having nucleation sites 104. Some bubbles or blisters are left behind as bumps 142. It is contemplated that the coating 108 of this embodiment comprises individual material particles having a higher boiling point than a base material of the coating to promote skin formation prior to a phase transformation from liquid to gas and blister formation.

[0088] In one embodiment, crazing is utilized to produce nucleation sites 104. Here, mechanical alteration of a material used to produce the container 1, for example, aluminum, is performed after the primary coating 108 is cured on product side 34 of the containment space 42 of the container 1. This mechanical work on the material can be transferred to theAttorney Docket No. 6365.152516PCTC115 primary coating 108 causing stress in the primary coating 108. The stress causes thickness differential in the coating 108 in the form of cracks or crazing in the primary coating 108. The cracks or crazing form nucleation sites. A bottom dome of a container body 40 is an example of a location susceptible to coating cracking or crazing in the primary coating 108 during a bottom reform operation when mechanical work is applied to the container material.

[0089] According to this embodiment, to prevent metal exposure, a secondary coating 120 may be applied to an exposed surface of the primary coating 108 on the product side 34 of the containment space 42, opposite a surface of the primary coating in contact with the container wall, especially in an area where the mechanical work is applied . A layer next to the aluminum has superior flexibility and does not crack during the mechanical alteration and prevents corrosion. The second layer is more brittle and experiences crazing and cracking.

[0090] Referring to FIGS. 14-17, the product side 34 of the containment space 42 may comprise a primary coating 108 and a secondary coating 120 on an otherwise exposed surface of the primary coating 108 within the containment space 42, where the secondary coating 120 comprises the nucleating surface 100 and nucleation sites 104. Chemically, the secondary coating 120 may be identical or different than the primary coating 108.

[0091] It follows that the nucleating surface 100 formed by or on the secondary coating 120 can be provided in clusters or galaxies 144 of nucleation sites 104 as described above.

[0092] In one embodiment, a nucleating surface 100 is formed by the secondary coating 120 which is applied to an existing primary coating 108 on the product side 34 of the containment space 42 of the container 1. Here, the secondary coating 120 is added to an exposed surface of the non-nucleating surface primary coating 108 of the container 1. The secondary coating 120 is added material and can be another a coating comprising the features and elements described above to create thickness differentials in the secondary coating (i.e., inclusions, etching, crater, etc.).

[0093] In one embodiment, nucleation sites 104 are created on at least one of the primary coating 108 or the secondary coating 120 when exposed to an energy from a source of energy. The source of energy may be different electromagnetic wavelengths ranging from visible light to gamma rays to e-beam or heat (as in a temperature increase). The energy can be applied to a filled and sealed container 1.

[0094] In one embodiment, the secondary coating 120 is etched, preferably by a laser, to form nucleation sites 104 on the secondary coating 120. Etching methods may include chemical etching, mechanical etching, for example, using brushes, or lasers.Attorney Docket No. 6365.152516PCTC116

[0095] In one embodiment, a nucleating surface 100 is formed by the secondary coating 120 which is applied to an existing primary coating 108 on the product side 34 of the containment space 42 of the container 1. Here, the secondary coating 120 is added to an exposed surface of a non-nucleating surface of the primary coating 108 of the container 1. The secondary coating 120 comprises a nucleating material such as inclusions 112 of a wax, silica, or other particles. The inclusions 112 may be suspended in a thin layer of a binder material such that the inclusions 112 are attached to the containment space 42. Thus, it is contemplated that the secondary coating 120 may comprise inclusions suspended in a binder. Alternatively, the binder layer may have a greater thickness and appear as an encrusted glue strip in the containment space 42. It is further contemplated that the secondary coating 120 may consist of inclusions 112 which are embedded in the primary coating 108.

[0096] In one embodiment, the secondary coating 120 is formed by inclusions 112 in the form of discrete individual solid particles distributed within the primary coating 108 and exposed to an energy from a source of energy. A chemical reaction within the solid particles causes the solid particles to transform from a solid to a gas resulting in either a bubble protrusion or a burst bubble void depending on the surrounding material surface tension and strength, thus creating a raised bubble or a recessed crater in the secondary coating 120.

[0097] According to the embodiments comprising a secondary coating 120, the secondary coating 120 may be applied during container manufacture or immediately before filling at the filling location. The secondary coating 120 could be a preformed decal or sticker 124 that is applied to a surface within the containment space 42. The secondary coating 120 may be on a preformed disk that is deposited into the containment space. The secondary coating 120 may be part of an existing gas-carrying secondary compartment to compliment that technology.

[0098] Further according to these embodiments, the secondary coating 120 may be applied to a non-nucleating surface of the containment space 42 of the container 1 when the primary coating 108 is applied to the product side 34 of the containment space 42 and still liquid, semi-liquid, and / or uncured or under-cured. An apparatus for applying the primary coating 108 comprising a spray gun may be operated to further supply the secondary coating 120. This may be accomplished by providing an additional spray gun to an existing apparatus. It is further contemplated that the secondary coating 120 may comprise dry particles that use the primary coating 108 as an adhesive. The particles may not be top coated with a binder and are, therefore, in direct contact with the beverage product during filling.Attorney Docket No. 6365.152516PCTC117

[0099] In one embodiment, the nucleating surface 100 is provided by a reticulating coating 124. Reticulating coatings are used on a container’s public side over-varnish coating to achieve different tactile effects ranging from satin and matte micro-finishes to deeper undulating surfaces. The tactile effect is often caused by chemical reactions between specialty decoration ink and specialty over-varnish on the public side 32 of the container 1. To achieve a reticulated coating 124 within a containment space 42 of a container, a secondary coating 120 is applied over a primary coating 108 while the primary and secondary coatings 108,120 are in a liquid state and a chemical reaction can occur. The chemical reaction causes a nucleating surface 100 to form when the primary and secondary coatings 108,120 cure. The curing of the primary and secondary coating 108,120 causes thickness differentials which are configured, as in sized and shaped, to function as nucleation sites 104.

[0100] In one embodiment, one or more of the primary or secondary coatings 108,120 located within the containment space 42 of a container 1 is etched, preferably by a laser, to form nucleation sites 104 on the primary or secondary coatings 108,120. Etching methods may include chemical etching, mechanical etching, for example, using brushes, or lasers. Alternatively, a base material used to form the container can be etched prior to application of the primary coating 108. In the case of a laser, only portions of a coating thickness are removed so that metal is not exposed after coating to alleviate corrosion concerns.

[0101] In one embodiment, the nucleating surface 100 is added to the containment space 42 after the containment space 42 has been filled with a beverage and the container 1 has been sealed with a lid 10 or other substantially fluid-tight closure.

[0102] In one embodiment, the container 1 includes a turbulent package orifice 130. Typically, metallic beverage container openings are optimized to reduce turbulence and promote smooth / fast pouring. According to this embodiment, a container 1 having a containment space 42 filled with a still (non-carbonated) beverage, which has limited or no nucleation ability, can be treated with liquid nitrogen, and a turbulence of the beverage upon opening the sealed container 1 is caused so that the beverage produces a foamy head 204 in the consumer’s mouth. For example, a plastic over-cap feature to create turbulence.

[0103] Further according to this embodiment, Applicant has previously produced a container opening that comprises a matrix of small apertures instead of a standard opening comprising a single large pour aperture. This opening comprising a plurality of small apertures promotes turbulence and nucleation. Additionally, such an opening can be sealed with a heat seal foil 138, produced from aluminum or other suitable material, rather than a score line opening as described above. The heat seal foil 138 typically comprises a coating,Attorney Docket No. 6365.152516PCTC118 such as a plastic coating, which softens or melts to create adhesion with the public side 32 of the lid 10.

[0104] Additionally, the nucleating surface 100 of this embodiment may include a coating around the small apertures. The coating can be either or both of the primary coating 108 and a secondary coating 120.

[0105] It is difficult to seal pressurized containers having an opening of a single large pour aperture with a heat seal foil because heat seal foils fail due to the pressure acting on a large surface area of the foil. The adhesion force at the rim of the pour aperture may be insufficient, and the internal pressure force acting on the foil will overcome the adhesion force. Additionally, the foil material will often strain and burst.

[0106] Covering a matrix of a plurality of small apertures allows for a foil seal to adhere between all of the apertures. The same internal can pressure results in a much smaller force for each individual aperture, and surface adhesion to the adjacent surfaces of a center panel of a can end or lid is adequate / dominant. With an adequate headspace 59, a pressure increase in nitrogenated (ideal gas) beverage (as compared to carbonation) is not extreme at typical pasteurization temperatures. Optimizing heat sealable peal strength vs. burst / leak resistance is easier for a nitrogen pasteurization temperatures. In the case of nitro foamed cocktail drinks, the small apertures resemble a familiar bartender shaker geometry.

[0107] In one embodiment, a beverage is modified to promote dissolved nitrogen to nucleate. Anti-foaming agents are used commercially to reduce foaming in aggressively foaming products. These anti-foaming agents generally cause a higher rate of gas loss per time and cause the resultant bubbles to collapse. One or more anti-foam agents may be added after filling and before seaming, along with the liquid nitrogen dosing.

[0108] In one embodiment, low levels of carbonation (approximately 1 gas volume of carbon dioxide) in combination with nitrogen are provided to achieve a stable and beneficial condition foamy head 204. Certain proteins are known to “bind” to bubbles and prevent foam from breaking up. The foam would continue to build. Alternate gases and gas concentrations can be provided to change a nucleation rate and a foam quality. The gases may be chosen from the group consisting of carbon dioxide, nitrogen, nitrous oxide, argon, and combinations thereof. Other gases can be tested as well. Gas solubility within a given beverage ingredient changes the beverage experience. Nitrous oxide solubility in fat is critical to whipped cream.

[0109] In one embodiment, a foaming agent is introduced into a containment space 42 of the container 1 during an application of a primary coating 108. Here, small gas bubbles,Attorney Docket No. 6365.152516PCTC119 preferably microbubbles, for example, of carbon dioxide and nitrogen, are injected into the primary coating 108 prior to being sprayed on the product side 34 of the containment space 42 of the container 1. Once on the product side 34, the gas bubbles can be heated causing the bubbles to enlarge. Depending on a volume of gas and a surface tension / strength of the surrounding primary coating material, each bubble cures as a bump or bursts to create a void. The location of each bump or each void serves as a nucleation site 104.

[0110] In one embodiment, a food grade foaming agent is introduced into the container 1.[OHl] One embodiment is directed to a method of filling a containment space of a container with a beverage, where the container 1 features one or more of the previously described features that promote nucleation of a foamy head 204, including formation of nucleation sites 104 within the containment space 42. A liquid beverage product is pumped to a filling head. Nitrogen is not purposely dissolved in the beverage produce; however, there is typically a cover gas in a holding tank that prevents oxidation and provides a pumping force to the filler head. A small amount of nitrogen will be in solution due to this nitrogen pressure. Alternatively, a small concentration of carbon dioxide may be desired as is common with some beverages (typically less than roughly 1 gas volume of carbon dioxide). In which case the cover gas will be carbon dioxide instead of nitrogen.

[0112] A fill height of the container 1 is less than the nominal container fill volume to allow for foam production without overflow, for example fill to 11.5 ounces in a nominal 12 ounce container. The volume is dependent upon beverage specifications, for example, volume of desired foam, risk tolerance for overflow compared to maximum foam production, and is not critical to functionality of the present container 1. For reference, a container 1 containing a secondary compartment, for example a foaming widget, may be filled to 9.6 ounces in a 12 ounce container; however, that is partially due to the volume consumed by the secondary compartment the method of “charging” the secondary compartment with gas.

[0113] Once the container 1 is filled, the filling head commonly releases pressure slowly so that any foaming from dissolved gas is minimized prior to a seaming operation which attaches the can end or lid to the container body 40. The nucleation sites will not produce any bubbles at this time due to a lack of any or minimal dissolved gas.

[0114] Immediately before seaming, a liquid nitrogen doser dispenses a volume of liquid nitrogen to the containment space 42, preferably to the beverage product within the containment space 42, more preferably to a top surface 202 of the beverage product 200. A liquid nitrogen dose 300 for an industry standard still beverage, for example, still water, wine, cocktail, coffee products, etc., will be enough to pressurize the filled container to 5-10 psi atAttorney Docket No. 6365.152516PCTC12035° F to increase package rigidity, and prevent shipping / handling damage. According to this embodiment, a volume of the liquid nitrogen dose 300 can be increased to increase the sealed container pressure to achieve nucleation and foam goals. Here, also, a headspace 59 above the top surface 202 of the beverage 200 is >5%, more preferably >9% of a total volume of the containment space 42, preferably >9.4%.

[0115] Nitrogen behaves like an ideal gas. A relationship between a product temperature / density similar to water, 53 psig at 35° F (beverage consumption temperature) will yield about 60 psig at room temperature (70° F). This represents an absolute maximum that a commercial customer would likely be able to pressurize a container without beginning to incur major package overpressure risks. Process variation (fill level and gas concentration) or high summertime distribution temperatures (up to 140° F) could cause package damaging pressure spikes. According to the present disclosure 30-40 psig (at 35° F) is the preferred pressure range.

[0116] Immediately after the liquid nitrogen is introduced into the containment space 42 of the filled container 1, preferably dropped onto the top surface 202 of beverage 200, the can end or lid 10 is placed onto the filled container body 40 and attached thereto, for example, by a seaming operation, which seaming operations are well known in the beverage filling art.

[0117] As the liquid nitrogen evaporates within the filled, dosed, and now-sealed container 1, it creates pressure within the container. The process of dissolving nitrogen into the beverage product takes time and initially all nitrogen is in gas form in the headspace 59. As the nitrogen dissolves into solution, eventually the headspace 59 and liquid will be in equilibrium. Dissolving nitrogen reduces nitrogen in the headspace 59, and so the overall internal container pressure will drop. This initial container pressures vs. aged / equilibrated container pressure must be calibrated to arrive at a desirable product and level of foaming. For example, with a larger volume headspace 59, there is less pressure differential between the pre and post dissolved nitrogen container pressure. For that reason, a larger headspace 59 (>9.4% of the total containment space volume) is also preferred to prevent the container 1 from over pressuring at the time of filling. In hot fill, a common headspace is approximately 9.5%. This reduces the pressure spike associated with a minimal nitrogen dose 300 at 185° F. A similar target is likely good for reducing our overdosed nitrogen can pressure spike.

[0118] With the beverage and headspace 59 nitrogen in equilibrium, nucleation sites 104 are “primed”. Upon opening the container, the dissolved nitrogen will begin to form bubbles at nucleation sites 104 within the containment space 42. As bubbles are formed, the total amount of nitrogen in solution decreases. The bubbles will continue to form at someAttorney Docket No. 6365.152516PCTC121 decreasing rate as the beverage is consumed and the dissolved nitrogen depletes. Bubbles combine at the beverage surface to produce high quality foam, preferably a micro-foam.

[0119] In one embodiment, a container body containment space, which is configured to hold and retain a beverage therein, is filled with a beverage. A lid is attached to the container body. A nucleating surface is located within the containment space. A seal substantially fluidically sealing the containment space formed by a combination of the container body and the lid. A gas is dissolved in the beverage within the containment space, wherein contact between the beverage and the nucleating surface causes an initial controlled foam to develop on a top surface of the beverage upon a removal of the seal.

[0120] In another embodiment, a solvent-bearing internal coating 108 prepared according to the present disclosure was applied to the product side 34 of container bodies 40. Three sections, approximately 1 inch x 1 inch, per sample were cut out of each sample of the container bodies 40. The samples were taken from an upper portion of the sidewall 60, a middle portion of the sidewall 60, and a lower portion of the sidewall 60. The samples were cleaned with isopropanol, dried with compressed air and then gold coated. The samples were then imaged using a scanning electron microscope (SEM). The general SEM settings were: SE detector, lOkV, 90 current, -15 tilt, ~30mm working distance and used the 4th aperture. (See FIGS. 21-24).

[0121] Referring to FIGS. 21-24, micrographs of the samples from the container bodies 40 are shown. The nucleation sites 104, comprising both craters 116 and bumps 142, are arranged in clusters or galaxies 144 comprising, on average, no fewer than about 5 nucleation sites 104 per cluster or galaxy 144. The density of clusters or galaxies is about 31 clusters or galaxies 144 per mm2, preferably greater than 31 clusters or galaxies 144 per mm2.

[0122] The container bodies 40 having nucleation sites 104 distributed as clusters or galaxies 144 produced according to this embodiment were tested for foaming and compared against container bodies having more uniformly distributed nucleation sites 104. The nucleation sites 104 were exposed to a lager. The results are summarized in Table 1.Attorney Docket No. 6365.152516PCTC122Table 1

[0123] Based on Table 1, the container bodies 40 having nucleation sites 104 distributed as clusters or galaxies 144 had a larger % of foam spilled out of the lid 10 due to the nucleating effect. Faming was 61% more effective than the samples having more uniformly distributed nucleation sites 104.

[0124] Based on this embodiment, the difference in uniform distributed nucleation sited 104 and nucleation sites 104 distributed as clusters or galaxies 144 leads to a difference in outcome of the product effect. It is believed the cluster or galaxy distribution of nucleation sites 104 is a contributing factor in larger foam generation.

[0125] It should be understood that nucleating coating is a known failure mode for traditional beverage containers by causing unacceptable gushing and loss of carbonated beverages between time of filling and seaming. Using this same anomaly to create a benefit to particular beverage categories is new and inventive. Recognizing that this technology is useful for nitrogenated products that the industry generally believes are incapable of selffoaming is also new and inventive. The industry only knows widgets (plastic) or shake method (user error). The present disclosure improves on both technologies.

[0126] The present disclosure delivers a consistent product.

[0127] Advantages of the invention over prior practice include reduced use of plastic and expensive assembly methods, as well as improved recyclability. Some beverage suppliers rely on consumers pouring a beverage hard down the center of a glass to agitate the product and cause nucleation. This method works well; however, it is not realistic for on-the-goAttorney Docket No. 6365.152516PCTC123 consumption where product is consumed directly from an unsealed container 1. The techniques for the most part can be utilized in bottles, cups, and cans.

[0128] Additionally, the industry is working to limit environmental impact associated with plastics. The current plastic widget offerings do not pose a threat to the aluminum recycling stream quality at current production levels. However, eliminating plastic while still providing the nitro beverage experience is a positive step in sustainability.

[0129] The present disclosure also results in manufacturing cost savings. Assembling a secondary compartment, like a widget, is machine and capital expense intensive. A coating based solution likely has lower manufacturing constraints. In global regions where widgets do not exist, a coating based solution would provide a lower barrier to entry than widget assembling machines.

[0130] Further, small pour openings on bottles do not permit widgets that are commonly used by aluminum can manufacturers, however resealable bottles are an ideal candidate for this technology. Between sips of beverage, the container 1 can be reclosed which prevents 1) the nitrogen from leaving the beverage before the product is fully consumed (going flat) and 2) allows beverage manufacturers to be more aggressive in volume of foam they can generate without risk of overflowing over several minutes.

[0131] Sill further, principles of the present disclosure can be used on cups. Nitrogenated coffee is a well-known product that is dispensed at coffee shops. The pouring technology and nitrogen content allow for a rich, creamy foam, preferably a micro-foam to form on top of the product. However, after pouring, the lack of nucleation sites in a standard cup does not allow for continual nitrogen foam production while consuming. The foam may be consumed early in the drinking process and the end of the beverage is flat with no foam. An aluminum cup with a nucleation coating would allow the beverage to continually bubble any remaining nitrogen that is in solution so that some foam may still be present at the end of the beverage. A better drinking experience is had.

[0132] A method of filling any of the containers 1 described above is illustrated in FIG. 25. Any container 1 as described above, comprising any of the features described above, is provided. Preferably, the container 1 is of a type that is subsequently sealed, for example the two-piece beverage containers illustrated in FIGS. 1-7. It should be understood, however, that unless specifically described and / or claimed, the container 1 provided can be any container, including all those described above and any other container suitable for holding a beverage.Attorney Docket No. 6365.152516PCTC124

[0133] During the filling process, nitrogen gas is used to flush out the internal contents of the nucleating coating can before the containment space is filled. In doing this, the gas seed that propagates the nucleating when the sealed container 1 is opened, becomes nitrogen instead of CO2. Nitrogen, being less soluble than CO2 is better able to survive and remain intact during high temperature pasteurization. This results in a better foaming effect after pasteurization.

[0134] Currently, known filling processes using nucleating coating cans do not differ from normal production. This invention is a deviation from standard filling process for beer with the nucleating coating can. Normal production does not include flushing with Nitrogen or any gas prior to filling. Typically, CO2 is used to purge the can prior to filling. Since pasteurization is commonly used in the field of beer manufacturing, it has been noted that high temperatures during this process diminishes the effect of nucleation. It is believed that the CO2 gas bubbles from the beer are absorbed into the liquid beverage during high temperature pasteurization due to the high solubility of CO2 into, for example, beer. Nitrogen flushing is an attempt to replace the atmospheric gas present in the container before filling and thus replace the “seed” of CO2 gas located on each nucleation site with a less soluble nitrogen gas bubble. This prevents the gas from being absorbed into the beer during high temperature pasteurization and thus still being present during opening to create the foaming effect.

[0135] A stream of a fluid is introduced into the containment space 42 of the container 1. The fluidic stream is a gaseous phase stream under pressure, between 50 to 100 psi (0.34 MPa to 0.69 MPa), and comprises nitrogen. Nitrogen makes up greater than 78% of stream, preferably between 80% to 100%, and more preferably substantially 100% of the stream. Here, the term “substantially” included at least 99.5% nitrogen. The containment space 42 is substantially empty prior to the introducing a nitrogen stream step. Here, the term “substantially” is intended to encompass a volume of the containment space 42 being at least 95% free of any liquids or solids.

[0136] A purpose of introduction of a nitrogen stream under pressure to a beverage-free container 1 is to flush a contents, typically mainly air, of the otherwise empty containment space 42 prior to filling the containment space 42 with a beverage. Referring to FIGS. 26 and 27, prior to the introducing the nitrogen stream step, the nucleating surface 100 comprises a plurality of nucleation sites 104 wherein at least one nucleation site 104 in the plurality of nucleation sites 104 comprises a volume of air within a crater. The introducing the nitrogen stream step flushes the volume of air from the crater and replaces the volume of air with aAttorney Docket No. 6365.152516PCTC125 volume of nitrogen. “Filling” refers to introduction of a beverage into the containment space 42. “Filling” does not necessarily require 100% of the volume of the containment space 42 to be occupied by the beverage, as is known in the art.

[0137] After the containment space 42 is flushed by the fluidic stream, the containment space 42 is filled with a beverage 200. The beverage 200 may be any beverage described above, for example a still beverage, a carbonated beverage, or a fermented beverage. For this method, the beverage is preferably a beer, including, but not limited to, lagers, ales, stouts, pilsners, porters, bocks, helles, saison, gose, malts, etc., where it is desirable to develop / produce a controlled foam 204 on the top surface 202 of the beverage 200 when a seal is removed during opening of the container 1. The foam 204 is preferably a micro-foam as described above.

[0138] Optionally, as described above, the method may include the step of depositing a dose 300 of liquid nitrogen on the beverage 200 within the containment space 42 prior to substantially fluidically sealing the beverage 200 in the containment space 42; a fluid may be dissolved in the beverage 200 within the containment space 42; and the beverage 200 may comprise at least one of a foaming agent and an anti-foaming agent.

[0139] Once the containment space 42 is filled with the beverage 200, the beverage 200 is enclosed within the containment space 42 by forming a substantially fluid-tight seal over an open end of the container to substantially fluidically seal the beverage 200 in the containment space 42. The substantially fluid-tight seal is as defined above.

[0140] The containment space 42 can be enclosed with any of the lids 10 described above. For example, the substantially fluid-tight seal can be created by the lids 10 as illustrated in FIGS. 1-4, which are seamed or double seamed to a container body 40. Alternatively, the lid 10 can be the threaded lids 10 illustrated in FIGS. 5-7. In either case, a headspace as described above is created between a top surface of the beverage 200 and a product side 34 of the lid 10.

[0141] After the beverage 200 is enclosed within the containment space 42, the beverage 200 is pasteurized. The pasteurization requires heating the beverage 200 to a pasteurization temperature and holding the beverage at the pasteurization temperature for a predetermined duration of time. The pasteurization temperature is typically between 140° F to 180° F (60° C to 82° C), preferably 140° F to 162° F (60° C to 72° C). The duration of time is typically to 15 seconds at the high end of the pasteurization temperature range to upwards of 30 minutes at the low end of the pasteurization temperature range.Attorney Docket No. 6365.152516PCTC126

[0142] While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.

Claims

Attorney Docket No. 6365.152516PCTC127CLAIMSWhat is claimed is:

1. A method of filling a containment space (42) of a beverage container (1) comprising the steps of: providing a container (1) comprising a containment space (42), the container (1) having a product side (34) and a public side, the product side having a nucleating surface (100) thereon; introducing a nitrogen stream under pressure into the containment space (42) to flush the containment space (42); and filling the containment space (42) with a beverage (200) subsequent to the introducing the nitrogen stream step.

2. The method according to Claim 1, wherein the introducing the nitrogen stream step flushes a contents from the containment space (42) prior to the filling the containment space (42).

3. The method according to any preceding claim, wherein the nitrogen stream is a gas.

4. The method according to any preceding claim, wherein the nitrogen stream is greater than 78% nitrogen.

5. The method of any preceding claim, wherein the nitrogen stream is between 80% and 100% nitrogen.

6. The method of any preceding claim, wherein the nitrogen stream is substantially 100% nitrogen.

7. The method according to any preceding claim further comprising the step of enclosing the beverage (200) within the containment space (42) by forming a substantially fluid-tight seal over an open end of the container (1) to substantially fluidically seal the beverage (200) in the containment space (42).

8. The method according to any preceding claim further comprising the steps of: heating the beverage (200) to a pasteurization temperature; andAttorney Docket No. 6365.152516PCTC128 holding the beverage (200) at the pasteurization temperature for a predetermined duration of time.

9. The method of any preceding claim, wherein the nucleating surface (100) comprises a plurality of nucleation sites (104).

10. The method of Claim 9, wherein the nucleation sites (104) are arranged in clusters (144), each cluster (144) comprising a subset of the plurality of nucleation sites (104).

11. The method of Claim 10, wherein each subset comprises at least 5 nucleation sites (104).

12. The method of Claim 11, wherein a density of the clusters (144) is at least 31 clusters (144) per mm2.

13. The method of Claim 12, wherein each cluster (144) is separated from an adjacent cluster (144) by an area free of nucleation sites (104), wherein a total area free of nucleation sites (104) is less than a total area of the clusters (144).

14. The method of Claim 13, wherein the product side of the containment space (42) comprises a primary coating (108), wherein the primary coating (108) comprises the nucleating surface (100), and the area free of nucleation sites (104) is formed from the primary coating (108).

15. The method of Claim 14, wherein each of the plurality of nucleation sites (104) is formed by a differential thickness in the primary coating (108).

16. The method of Claim 15, wherein the plurality of nucleation sites (104) comprise at least one of a plurality of bumps (142) and a plurality of craters (116).

17. The method of Claim 16, wherein the primary coating (108) comprises inclusions, wherein the inclusions create the plurality of nucleation sites (104).

18. The method of Claim 17 wherein the inclusions comprise a plurality of solid particles.

19. The method of Claim 18, wherein the plurality of solid particles comprises at least one of a wax, spherical in shape, a raised conic shape, and a conic-shape with a divot.Attorney Docket No. 6365.152516PCTC12920. The method of Claim 13, wherein the nucleating surface (100) is formed by deforming a container wall of the container (1).

21. The method of Claim 20, wherein the container wall is deformed by one or more of a laser etching, a chemical reaction, a mechanical embossing, and a mechanical debossing.

22. The method of Claim 13, wherein the primary coating (108) comprises a polyolefin dispersion.

23. The method of Claim 22, wherein the polyolefin dispersion forms random swirls causing a differential thickness in the primary coating (108) forming the nucleating surface (100).

24. The method of Claim 23, wherein the differential thickness is caused by a solvent in the primary coating (108), wherein the solvent transforms from a liquid to a gas during curing of the primary coating (108) to produce the at least one of the plurality of bumps (142) or the plurality of craters (116).

25. The method of Claim 13, wherein each of the plurality of nucleation sites (104) is formed by at least one of cracks in the primary coating (108) and crazing in the primary coating (108).

26. The method of Claim 13, wherein the primary coating (108) comprises deformations caused by one or more of a laser etching, a chemical reaction, a mechanical embossing, and a mechanical debossing, wherein the deformations form each of the plurality of nucleation sites (104).

27. The method of Claim 12 further comprising a primary coating deposited on the product side of the containment space (42) and a secondary coating (120) located on an otherwise exposed surface of the primary coating (108) opposite a surface of the primary coating (108) in contact with the container wall, wherein the secondary coating (120) comprises the plurality of nucleation sites (104).

28. The method of Claim 27, wherein the secondary coating (120) comprises inclusions, wherein the inclusions create the plurality of nucleation sites (104).Attorney Docket No. 6365.152516PCTC13029. The method of Claim 28, wherein the inclusions comprise a plurality of solid particles.

30. The method of Claim 29, wherein the inclusions are suspended in a binder.

31. The method of Claim 30, wherein the secondary coating (120) comprises a decal.

32. The method of Claim 31, wherein the secondary coating (120) is a reticulating coating.

33. The method of Claim 33, wherein the secondary coating (120) comprises deformations caused by one or more of a laser etching, a chemical reaction, a mechanical embossing, and a mechanical debossing, wherein the deformations form each of the plurality of nucleation sites (104).

34. The method according to Claim 7, wherein contact between the beverage (200) and the nucleating surface (100) causes a controlled foam (204) to develop on a top surface (202) of the beverage (200) when the seal is removed.

35. The method according to Claim 34, wherein the foam (204) is a micro-foam.

36. The method according to Claim 7, wherein the seal is provided by a lid (10) having threads attached to a container body (40).

37. The method according to Claim 7, wherein the seal is provided by a lid (10) seamed to a container body (40).

38. The method according to Claim 36 or Claim 37, wherein the lid is produced from a metallic material.

39. The method according to Claim 38, wherein the metallic material is an aluminum alloy.

40. The method according to Claim 36 or Claim 37, wherein a headspace is located in the containment space (42) between the top surface (202) of the beverage (200) and the product side (34) of the lid (10), wherein the headspace has a volume that is equal to or greater thanAttorney Docket No. 6365.152516PCTC13141. The method according to Claim 38 wherein the headspace comprises undissolved nitrogen.

42. The method according to any preceding claim further comprising the step of depositing a dose (300) of liquid nitrogen on the beverage (200) within the containment space (42) prior to substantially fluidically sealing the beverage (200) in the containment space (42).

43. The method according to any preceding claim, wherein a fluid is dissolved in the beverage (200) within the containment space (42).

44. The method according to any preceding claim, wherein the beverage (200) comprises at least one of a foaming agent and an anti-foaming agent.

45. The method according to Claim 1, wherein the container (1) comprises a primary coating (108) deposited on the product side (34) of the containment space (42), wherein the primary coating (108) comprises the nucleating surface (100), or a secondary coating (120) is located on an otherwise exposed surface of the primary coating (108) opposite a surface of the primary coating (108) in contact with the product side (34) of the containment space (42), wherein the secondary coating (120) comprises the nucleating surface (100).

46. The method according to Claim 1 wherein the container (1) is a metallic cup.

47. The method according to Claim 1, wherein the container (1) is a two-piece beverage container (1).

48. The method according to Claim 8, wherein the pasteurization temperature is between 140° F to 180° F (60° C to 82° C).

49. The method according to Claim 48, wherein the pasteurization temperature is between 140° F to 162° F (60° C to 72° C).

50. The method according to any of Claims 8, 48, and 49, wherein the predetermined duration of time is between 15 seconds and 30 minutes.

51. The method according to any preceding claim, wherein the beverage (200) is beer.Attorney Docket No. 6365.152516PCTC13252. The method according to any preceding claim, wherein the container is produced from a metallic material.

53. The method according to any preceding claim, wherein the container is produced from an aluminum alloy.

54. The method according to any preceding claim, wherein the containment space is substantially empty prior to the introducing a nitrogen stream step.

55. The method according to any preceding claim, wherein a pressure of the nitrogen stream is delivered at between 50 psi to 100 psi.

56. The method according to Claim 1, wherein, prior to the introducing the nitrogen stream step, the nucleating surface comprises a plurality of nucleation sites wherein at least one nucleation site in the plurality of nucleation sites comprises a volume of air within a crater, wherein the introducing the nitrogen stream step flushes the volume of air from the crater and replaces the volume of air with a volume of nitrogen.

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