[0001] This application claims priority to and any benefit of U.S. Provisional Application No. 61/733,152, filed December 4, 2012, the entire contents of which are incorporated by reference in its entirety.

BACKGROUND

[0002] This disclosure relates to a closure for a product container and sterilization methods. The closure, product container, and methods can be used with, among other things, beverage products, nutritional products, and pharmaceutical products. In some closure and container designs a hermetic seal is provided between the closure and the container. The sealed container can then be subjected to retort sterilization conditions, during which the hermetic seal must survive sterilization of the product and the container. In some circumstances it may be desirable to manufacture product closures and containers from plastics such as polypropylene, high density polyethylene, and polyester terephthalate. A concern with plastic closures and containers used with retort sterilization processes is that the heat during retort conditions can damage or deform the plastic, causing issues in achieving and maintaining a proper hermetic seal. Accordingly, it is desirable to provide a closure for a container and a sterilization process where the structural integrity of the container and closure is maintained, while providing a hermetic seal and allowing the container to opened with relative ease at the time of the product's intended use.

[0003] While a variety of closures for containers and methods for sterilizing such closures and containers have been made and used, it is believed that no one prior to the inventor(s) has made or used an invention as described herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] While the specification concludes with claims that particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description of certain examples taken in conjunction with the

accompanying drawings, in which like reference numerals identify the same elements.

[0005] FIG. 1 depicts a perspective view of an exemplary container and closure, with the closure having a sealing disk and torque ring.

[0006] FIG. 2 depicts a perspective view of a portion of the container of FIG. 1, shown with a top portion of the closure removed and a bottom portion of the closure remaining on the container.

[0007] FIG. 3 depicts a perspective view of a portion of the container of FIG. 1, shown with the top and bottom portions of the closure removed.

[0008] FIG. 4 depicts a top perspective view of the bottom portion of the closure.

[0009] FIG. 5 depicts a bottom perspective view of the bottom portion of the closure, shown with a ratcheting portion folded outward.

[0010] FIG. 6 depicts a top view of the top portion of the closure of FIG. 1.

[0011] FIG. 7 depicts a bottom view of the top portion of the closure shown in FIG.

6.

[0012] FIG. 8 depicts a section view of the torque ring of the top portion of the closure shown in FIG. 7 taken along line 8— 8.

[0013] FIG. 9 depicts a top perspective view of the sealing disk of the closure of

FIG. 1.

[0014] FIG. 10 depicts a bottom view of the sealing disk of the closure of FIG. 1.

[0015] FIG. 11 depicts an exemplary method for sterilizing the closure and the container of FIG. 1. [0016] FIG. 12 depicts another exemplary method for sterilizing the closure and the container of FIG. 1.

[0017] FIG. 13 depicts an exemplary device, shown schematically, to sterilize the closure and the container according the method of FIG. 12.

[0018] The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

[0019] The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

I. Exemplary Container

[0020] FIGS. 1-3 illustrate a closure (100) for a container (200). Container (200) comprises a threaded neck (202), a middle flange (204), a ratcheting portion (206), and a lower flange (208). Ratcheting portion (206) comprises teeth (210) that are configured to engage with a portion of closure (100) as further described below.

II. Exemplary Closure

[0021] As seen from FIGS. 1-3, closure (100) is removable from container (200). In the present example, closure (100) is a two-piece design, although few or more piece designs can be used. In the illustrated version, closure (100) comprises torque ring (101) and sealing disk (103). A. Exemplary Torque Ring

[0022] Torque ring (101) comprises top portion (102) and bottom portion (104). Bottom portion (104) comprises a locking ring (106). Locking ring (106) is attached to top portion (102), but upon removal of closure (100) from container (200), locking ring (106) is held down by middle flange (204) so that it separates from top portion (102) and remains with container (200) as seen in FIG. 2. This separating locking ring (106) provides evidence of tampering by indicating whether closure (100) has previously been opened. This separation of locking ring (106) is facilitated by the initial attachment of locking ring (106) to top portion (102) being perforated. Locking ring (106) is further configured to engage with ratcheting portion (206) of container (200) as described further below. This engagement during removal of closure (100) from container (200) holds locking ring (106) substantially stationary while top portion (102) is rotated thereby causing locking ring (106) to separate from top portion (102). In some other versions, torque ring (101) does not include locking ring (106), e.g., in situations where security of closure (100) is less important or the security is provided by other means such as a label securing the position of closure (100) to container (200) or by additional torquing of closure (100) onto container (200).

[0023] As illustrated in FIGS. 4 and 5, locking ring (106) comprises ratcheting portion (108). Ratcheting portion (108) comprises teeth (110). Teeth (110) are configured to engage with corresponding teeth (210) of container (200). This engagement of teeth (110) with teeth (210) provide for engagement of ratcheting portion (108) with ratcheting portion (206). Again, engagement of ratcheting portions (108, 206) enables separation of locking ring (106) from top portion (102) of closure (100) during removal of closure (100) from container (200).

[0024] As further illustrated from a comparison of FIGS. 4 and 5, ratcheting portion (108) of locking ring (106) is configured such that it is folded inward within the inner diameter of locking ring (106) such that ratcheting portion (108) is positionable adjacent to an inner surface (112) of locking ring (106). Folding of ratcheting portion (108) is achieved in the present example by a living hinge (114) that connects ratcheting portion (108) with the remainder of locking ring (106). FIG. 4 illustrates a view with ratcheting portion (108) in the inwardly folded position, while FIG. 5 illustrates a view with ratcheting portion (108) unfolded and outwardly extended from inner surface (112) of locking ring (106). In some versions, torque ring (101) is manufactured by injection molding, with ratcheting portion (108) being injection molded in its unfolded position along with the remainder of torque ring (101). After molding ratcheting portion (108) is folded to assume its position adjacent to inner surface (112) of locking ring (106). Referring back to FIG. 1, in the assembled configuration, living hinge (114) is positioned closest to lower flange (208) of container (200). In other versions locking ring (106) is molded with ratcheting portion (108) in the proper finished orientation such that ratcheting portion (108) does not need to be folded inward. In other words, teeth (110) of ratcheting portion (108) are molded in the inward orientation.

[0025] Top portion (102) of torque ring (101) comprises gripping surface (116) and rounded lip (118). In the illustrated version, gripping surface (116) comprises a plurality of protrusions (120) that are vertically oriented and generally equally spaced around the circumference of top portion (102). In other versions, gripping surface (116) comprises a plurality of protrusions (120) that are unequally spaced, and/or the protrusions (120) can be arranged in a variety of geometric patterns such as diamonds, dots, or random patterns. Gripping surface (116) increases friction between a person's fingers and closure (100) when the person is attempting to remove closure (100) from container (200). Rounded lip (118) of torque ring (101) in the illustrated version and defines the top of torque ring (101). In the illustrated version, rounded lip (118) takes the form of a generally half cylinder that curves around the top perimeter of torque ring (101).

[0026] FIGS 6 and 7 illustrate top and bottom views of closure (100), but shown without bottom portion (104) of torque ring (101) attached. As illustrated in FIG. 6, rounded lip (118) defines an opening in torque ring (101) and within that opening sealing disk (103) is positioned as described further below.

[0027] FIG. 8 illustrates a section of torque ring (101) revealing an interior surface (122) of torque ring (101). Interior surface (122) comprises threads (124) and flange (126). Also as seen in FIG. 8, is the profile of rounded lip (118) showing rounded lip (118) defines a curved groove (128) for receiving a corresponding portion of sealing disk (103). Threads (124) are configured to engage with threaded neck (202) of container (200) so that closure (100) can be screwed onto and off of container (200). When tightening closure (100) onto container (200), closure (100) is pulled downward toward lower flange (208) due to the threaded arrangement between closure (100) and container (200). When removing closure (100) from container (200), the opposite occurs, and closure (100) is driven upward away from lower flange (208). Flange (126) is configured as a retaining member for holding sealing disk (103) in place once sealing disk (103) has been connected with torque ring (101).

B. Exemplary Sealing Disk

[0028] In the present example, sealing disk (103) is connected with torque ring (101) to form closure (100) by press fitting sealing disk (103) within torque ring (101) from the underside of torque ring (101). As illustrated in FIG. 9, sealing disk (103) comprises rounded lip (130) that is configured to seat within the space between flange (126) and curved groove (128) of torque ring (101). Sealing disk (103) is held in position after connecting with torque ring (101) by an interference between underside edge (132) of sealing disk (103) and flange (126).

[0029] FIGS. 9 and 10 illustrate sealing disk (103) showing the top of sealing disk in FIG. 9 and the underside or bottom of sealing disk (103) in FIG. 10. As illustrated in FIG. 10 in addition to underside edge (132) and rounded lip (130) (viewable in FIG. 9), the present exemplary sealing disk (103) comprises gasket (134), raised annular ring (136), and center surface (138). It should be noted that the relative terms describing portions of sealing disk (103) as raised, depend on the view from which one examines sealing disk (103). For example, in FIG. 9 annular ring (136) appears raised relative to center surface (138), while from the underside view of FIG. 10, annular ring (136) appears recessed relative to center surface (138) which appears raised.

[0030] Gasket (134) of sealing disk (103) is made of an elastomeric material in the present example. Suitable materials for gasket (134) include, among others, rubber, plastic, vinyl, and silicone. In view of the teachings herein other suitable materials for gasket (134) will be apparent to those of ordinary skill in the art. Gasket (134) is positioned within the space defined by the underside of rounded lip (130) of sealing disk (103). When closure (100) is used with container (200), gasket (134) contacts an edge (212) of container (200) that defines the opening of container (200). When torque ring (101) is tightened down, sealing disk (103) is drawn toward edge (212) of container (200) and gasket (134) is compressed against edge (212) forming a hermetic seal.

[0031] In some versions, sealing disk (103) is configured such that annular ring (136) and center surface (138) are configured to behave as a vacuum button to provide assurance that the hermetic seal has not been broken. [0032] In the present example, sealing disk (103) is comprised of metal or plastic. In versions where sealing disk (103) is comprised of metal, the metal can be steel, stainless steel, or aluminum, although other metals can be used. The thickness of sealing disk (103) can be between 0.10 and 0.30 millimeters, of course other thicknesses can be used. In some versions where sealing disk (103) is comprised of plastic, sealing disk (103) comprises a multi-layer plastic such that sealing disk (103) provides an adequate oxygen barrier. In view of the teachings herein other suitable materials for sealing disk (103) will be apparent to those of ordinary skill in the art.

[0033] In some versions, sealing disk (103) comprises a coating (140) on the underside of sealing disk (103). Coating (140) can be approximately 0.015 millimeters thick, although other thicknesses can be used. Coating (140) can be applied by solvent coating systems or in other ways that will be apparent to those or ordinary skill in the art in view of the teachings herein. In some versions, coating (140) can be a fusible coating, e.g.

polypropylene, where coating (140) melts when sufficiently heated and then re-solidifies when cooled. With fusible coatings, coating (140) fuses the edge (212) of container (200) with sealing disk (103) to forms a hermetic seal. In versions having fusible coatings, coating (140) can extend to cover gasket (134) or gasket (134) can be positioned over coating, or gasket (134) can be omitted altogether.

[0034] Where fusible coatings are used with a metal version of sealing disk (103), the energy required to fuse coating (140) can be from exposing metal sealing disk (103) to a source of electromagnetic energy induced by an induction coil, such as an electromagnetic current, such that metal sealing disk (103) has its molecules excited so as to cause fusible coating (140) to melt and fuse sealing disk (103) with edge (212) of container (200) thereby forming a hermetic seal. In versions where fusible coatings are used with a plastic version of sealing disk (103), the energy required to fuse coating (140) can be from exposing plastic sealing disk (103) to a heat source such as an oven, ultrasonic vibration, radiation of some kind such microwave radiation, optical energy of some kind such as a laser. In view of the teachings herein, various ways to heat and cool a fusible coating (140) on either a metal or plastic sealing disk (103) will be apparent to those of ordinary skill in the art.

[0035] In some other versions coating (140) is not fusible and instead is compressible or flexible to provide an adequate seal when torque ring (101) is sufficiently tightened. Again, in versions where coating (140) is not fusible but is compressible or flexible, coating (140) can extend to cover gasket (134), or gasket (134) can be positioned over coating (140), or gasket (134) can be omitted altogether. Of course in some versions coating (140), whether fusible or not fusible, is omitted altogether.

[0036] In the present example, torque ring (101) and sealing disk (103) are connected in a way that sealing disk (103) is not immovably fixed to torque ring (101). For instance, when closure (100) is removed from container (200), sealing disk (103) can be held in place while torque ring (101) rotated. In the present example, this configuration is achieved because the space where sealing disk (103) is positioned within torque ring (101) (this space being defined between curved groove (128) and flange (126)) is slightly larger than the thickness of sealing disk (103) at rounded lip (130). In use, when torque ring (101) is tightened by moving downward via its threaded connection with container (200), the contact of sealing disk (103) with curved groove (128) will drive sealing disk (103) downward to ultimately contact container (200), even though sealing disk (103) may not rotate in unison with torque ring (101). When torque ring (101) is loosened by moving upward via its threaded connection with container (200), the contact of sealing disk (103) with flange (126) will drive sealing disk (103) upward to ultimately disconnect sealing disk (103) from container (200), again even though sealing disk (103) may not rotate in unison with torque ring (101). While sealing disk (103) may not rotate in unison with torque ring (101) at all times as described above, when there is sufficient contact between either sealing disk (103) and curved groove (128), or between sealing disk (103) and flange (126), sealing disk (103) can rotate in unison with torque ring (101).

[0037] Another exemplary closure for a container that can used with some of the methods described below is described in U.S. Patent 4,991,731, entitled Retortable

Composite Closure for Plastic Containers, issued February 12, 1991, and incorporated by reference herein. For instance, in some versions sealing disk (103) comprises a downwardly inclined portion and an upwardly inclined portion to form a center portion. The center portion then behaves as a vacuum button to further provide assurance that the hermetic seal has not been broken. In view of the teachings herein, other exemplary closures for containers and closures that can be used with the methods described below will be apparent to those of ordinary skill in the art.

[0038] While some of the above exemplary closures described have been constructed of two pieces— a torque ring and a sealing disk, the disclosure here is not intended to be limited to two piece closure designs. In fact the teachings herein are intended to apply equally to three piece closures, or more generally multi -piece closures. Still yet, the teachings may apply to single piece closures as well.

[0039] In the present example, the design of closure (100) and container (200) as described above in detail, permits opening a sealed container (200) in a single action. That is, removal of closure (100) provides immediate access to the contents of container (200) without the need to remove or puncture any additional seals.

III. Exemplary Methods

[0040] FIG. 11 illustrates that container (200) and closure (100), as disclosed herein, may be sterilized in a retort process (300). As depicted in step (310), sealing disk (103) and torque ring (101) are assembled as described above. Container (200) is filled with a nutritional, pharmaceutical, or other product, as shown in step (312). Prior to capping container (200), the head space in the container may be flushed with an inert gas to displace oxygen from the head space. Next, at step (314), closure (100) may be cooperatively engaged with container (200) by screwing on closure (100), which provides an application of downward movement and pressure to sealing disk (103)._In versions having coating (140) that is fusible, closure (100) may be subjected to a source of energy such that fusible coating (140) fuses sealing disk (103) to container (200) as described above. This fusing forms a hermetic seal between container (200) and closure (100). In versions without a fusible coating, but having a compressible coating (140) and/or a compressible gasket (134), tightening down torque ring (101) sufficiently will cause the compressible coating (140) of sealing disk (103) and/or will cause the compressible gasket (134) of sealing disk (103) to contact edge (212) of container (200) and compress to form a hermetic seal. Once assembled, the filled and sealed container is sterilized in a retort process, as shown in step (316). The filled and sealed container may be heated to retort conditions up to 275 °F. In some versions the retort conditions used involving heating the filled and sealed container to about 262 °F and holding at that temperature for 9-18 minutes. In view of the teachings herein, other retort conditions for sterilization will be apparent to those of ordinary skill in the art.

[0041 ] In some versions it may be desirable to sterilize container (200) and closure (100) in an aseptic process. For instance, aseptic sterilization processes may be gentler on container (200), closure (100), and/or the product contained or to be contained within the container. By way of example only, and not limitation, an aseptic sterilization process may be desirable where all or parts of container (200) and closure (100) are comprised of plastic components that may be subject to damage or deformation if held at high heat for extended times.

[0042] FIGS. 12 illustrates an exemplary process (400) for sterilizing container (200) and closure (100) in an aseptic process. Step (410) comprises preparing torque ring (101) for aseptic sterilization. More specifically, in versions where closure (100) comprises torque ring (101) having locking ring (106) and ratcheting portion (108), prior to and during aseptic sterilization ratcheting portion (108) is either not yet folded to be adjacent to inner surface (112) of locking ring (106), or unfolded from inner surface (112) of locking ring (106). In such versions, having ratcheting portion (108) in the unfolded position helps ensure that all surfaces of closure (100) are subjected to whatever aseptic processing conditions are used. Step (410) is optional in some versions. For instance, step (410) can be omitted in versions where torque ring (101) does not include ratcheting portion (108), or where after injection molding torque ring (101) ratcheting portion (108) is left in its unfolded state. Also, step (410) can be omitted where it has been demonstrated that the aseptic process used for sterilization is adequate to ensure sterilization of all surfaces of torque ring (101), even when ratcheting portion (108) remains in its folded position. Still yet, step (410) can be omitted in versions where ratcheting portion (108) is molded in the proper finished orientation with teeth (110) of ratcheting portion (108) in the inward orientation.

[0043] Next, step (412) comprises sterilizing unassembled sealing disk (103), torque ring (101), and container (200) in one or more aseptic processes. In some versions, the aseptic process includes subjecting one or more of the components to a hydrogen peroxide fog, a hydrogen peroxide bath, steam, ultraviolet light, or radiation such as electron beams, X-rays, gamma rays, etc. In some aseptic sterilization processes one or more components are subjected to temperatures of approximately 310 °F for 5-10 seconds. Other aseptic sterilization processes will be apparent to those of ordinary skill in the art in view of the teachings herein. In some versions torque ring (101), sealing disk (103), and container (200) all undergo the same aseptic sterilization process. In some other versions torque ring (101), sealing disk (103), and container (200) all undergo different aseptic sterilization processes. Still in some versions one or more of the torque ring (101), sealing disk (103), and container (200) can undergo one aseptic process while the other components undergo another aseptic process for sterilization.

[0044] In step (414), after being sterilized in an aseptic process, sealing disk (103) and torque ring (101) are assembled in an aseptic, or sterile, environment to form closure (100). Assembly of sealing disk (103) and torque ring (101) occurs as described above— by press fitting sealing disk (103) within torque ring (101) until sealing disk (103) is located into position between curved groove (128) and flange (126). In some versions, assembling sealing disk (103) to torque ring (101) involves snap-fitting sealing disk (103) within torque ring (101).

[0045] In step (416), also after being sterilized, torque ring (101) is prepared for container filling. More specifically, in versions of torque ring (101) having locking ring (106) and ratcheting portion (108), torque ring (101) is prepared by ratcheting portion (108) being folded such that ratcheting portion (108) is adjacent inner surface (112) of locking ring (106) as described above. In some versions step (416) occurs before assembling sealing disk (103) with torque ring (101). In some other versions step (416) occurs after assembling sealing disk (103) with torque ring (101).

[0046] In step (418), container (200) is filled with the desired product in an aseptic environment. In some versions where container (200) is filled with a fluid, the fluid is first treated in a pasteurization process or sterilized in a heat treatment, for example by passing the fluid through a heat exchanger. In view of the teachings herein, other ways to treat or sterilize the product prior to filling container (200) will be apparent to those of ordinary skill in the art.

[0047] Next, filled container (200) is capped and sealed in an aseptic environment, as shown in step (420). Closure (100) is engaged with container (200) via a threaded engagement as described above. By screwing closure (100) onto container (200), sealing disk (103) is positioned in contact with edge (212) of container (200). In versions where sealing disk (103) comprises coating (140), where coating (140) is fusible, closure (100) may be subjected to a source of energy such that sealing disk (103) is fused with edge (212) of container (200) to form a hermetic seal. In versions where sealing disk (103) comprises compressible gasket (134) or compressible coating (140) instead of, or in addition to fusible coating (140), screwing down torque ring (101) sufficiently drives sealing disk (103) against edge (212) of container (200) such that gasket (134) and/or compressible coating (140) press against edge (212) forming a hermetic seal. An optional step in either filling step (418) or capping step (420) is flushing the head space of container (200) with an inert gas to displace any oxygen from the head space prior to sealing container (200).

[0048] FIG. 13 illustrates an exemplary device, shown schematically, to sterilize closure (100) and the container (200) according the aseptic sterilization method of FIG. 12. In FIG. 13, disk feeder (510) feeds unassembled sealing disks (103) into sterilization cabinet (502). Ring feeder (512) feeds unassembled torque rings (101) into sterilization cabinet (502). As discussed above, torque rings (101) are prepared if necessary before being directed to the sterilization process. In FIG. 13, if necessary, ring preparer (511) prepares torque rings (101) prior to sending torque rings (101) to ring feeder (512). Container feeder (514) feeds unassembled containers (200) into sterilization cabinet (502).

[0049] The unassembled components— sealing disk (103), torque ring (101), and container (200)— are directed to an aseptic sterilization station (520) for aseptic sterilization according to step (412) of FIG. 12 as described above. The unassembled components may be sterilized in the same sterilization cabinet (502) as shown in the illustrated version of FIG. 13, or the unassembled components may be sterilized in separate sterilization cabinets, or combinations thereof. Suitable sterilization equipment configurations will be apparent to those of ordinary skill in the art based on the teachings herein.

[0050] Cap assembly station (530) performs step (414) as described above, and container filling station (532) performs step (418) as described above. As part of cap assembly station (350), if necessary, ratcheting portion (108) is folded upward to be adjacent inner surface (112) of locking ring (106) as described above in step (416) of FIG. 12. As part of either container filling station (532) or container capping station (540), if desired, the head space of a filled container (200) can be flushed with an inert gas to displace any oxygen in the head space after filling. Container capping station (540) performs step (420) as described above. After being capped and sealed by closure (100), container (200) may be removed from sterile cabinet (502) to provide a finished sealed container (550).

[0051 ] Having shown and described various embodiments of the invention disclosed herein, further adaptations of the methods and systems described herein may be accomplished by appropriate modification by one of ordinary skill in the art without departing from the scope of the invention disclosed herein. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, examples, embodiments, geometries, materials, dimensions, ratios, steps, and the like discussed above are illustrative. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.