WO2013009624A2

WO2013009624A2 - Metal container for holding food while cooking and method of making the same

Info

Publication number: WO2013009624A2
Application number: PCT/US2012/045764
Authority: WO
Inventors: Alvin Widitora; Gerald J. BAKER; Rowdy H. Holstine; Donald GUST
Original assignee: Silgan Containers, Llc
Priority date: 2011-07-08
Filing date: 2012-07-06
Publication date: 2013-01-17
Also published as: WO2013009624A3; US20140117024A1

Abstract

A metal can for holding food during cooking is provided. The metal can includes a metal sidewall having an upper end, a lower end and a midpoint. The metal sidewall has an inner surface defining an interior cavity of the can configured to hold food during cooking. The metal can includes a metal can end coupled to the lower end of the sidewall and a metal insert located within the interior cavity of the can. The metal insert includes a planar disc and an upstanding insert sidewall extending from a peripheral edge of the disc portion, and a radially outward facing surface of the insert sidewall engages the inner surface of the metal sidewall.

Description

METAL CONTAINER FOR HOLDING FOOD WHILE COOKING AND

METHOD OF MAKING THE SAME

CROSS-REFERENCE TO RELATED PATENT APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No.

61/505,878 titled "ROASTING CAN AND METHOD OF MAKING THE SAME," filed July 8, 2011, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

[0002] The present invention relates generally to the field of metal containers which are heated while food is in the containers. The present invention relates specifically to a metal container configured to hold food during cooking and more specifically to a metal container that holds a material, such as coffee beans, during roasting.

SUMMARY OF THE INVENTION

[0003] One embodiment of the invention relates to a metal can for holding food during cooking including a metal sidewall having an upper end, a lower end and a midpoint. The metal sidewall has an inner surface defining an interior cavity of the can configured to hold food during cooking. The metal can includes a metal can end coupled to the lower end of the sidewall and a metal insert located within the interior cavity of the can. The metal insert including a planar disc and an upstanding insert sidewall extending from a peripheral edge of the disc portion, and a radially outward facing surface of the insert sidewall engages the inner surface of the metal sidewall. The metal can further includes a circumferential bead formed in the metal sidewall, and the circumferential bead is located between the lower end and the midpoint of the metal sidewall. The circumferential bead extends radially inward defining a downward facing surface generally facing the lower end of the sidewall, and the insert sidewall includes an upward facing surface generally facing the upper end of the metal sidewall, and the upward facing surface of the insert sidewall engages the downward facing surface of the circumferential bead to hold the metal insert below the circumferential bead.

[0004] Another embodiment of the invention relates to a metal can for holding coffee beans during roasting including a metal sidewall having an upper end and a lower end. The metal sidewall has an inner surface which defines an interior cavity of the can that is configured to hold raw coffee beans during roasting. A can end is coupled to the lower end of the sidewall, and at least a portion of the sidewall is tapered between the upper end and lower end of the sidewall.

[0005] Another embodiment of the invention relates to a stirring insert configured to be coupled to the inner surface of a sidewall of a metal can configured to hold raw coffee beans during roasting. The insert having a body disc and a sidewall positioned at the periphery of the body disc extending away from the body disc. The stirring insert also including a stirring finger extending from the body disc.

[0006] Another embodiment of the invention relates to a method for producing a stirring insert for a coffee roasting can. The method includes the steps of providing a metal blank and forming a body disc and an upstanding sidewall from the metal blank. The upstanding sidewall is positioned at the peripheral edge of the body disc. The method includes cutting a slot through the body disc. The slot defines the peripheral edge of a stirring finger. The method includes pushing the stirring finger upward such that the stirring finger extends away from the body disc.

[0007] Yet another embodiment of the invention relates to a method for producing a coffee roasting can including the steps of providing a rectangular metal blank and forming a cylinder from the metal blank. The cylinder is shaped to form a tapered can sidewall, the sidewall having an open upper end, an open lower end and an upward facing surface located along the inner surface of the sidewall. The method includes coupling an end wall to the lower end of the sidewall and inserting a stirring insert through the open upper end of the sidewall such that the insert seats against the upward facing surface of the sidewall.

[0008] Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

[0010] FIG. 1 is a cross-sectional view of a container and insert according to an exemplary embodiment.

[0011] FIG. 2 is a cross-sectional view of a container according to an exemplary

embodiment.

[0012] FIGS. 3A-3D show production of the container insert of FIG. 1 according to an exemplary embodiment.

[0013] FIGS. 4A-4F show production of the container of FIG. 1 according to an exemplary embodiment.

[0014] FIG. 5 shows nesting of two containers according to an exemplary embodiment.

[0015] FIGS. 6A-6E show containers configured to engage an insert according to various exemplary embodiments.

[0016] FIG. 7 is a cross-sectional view of a two piece container according to an exemplary embodiment.

[0017] FIGS. 8A-8C shows the production of the two piece container of FIG. 7 according to an exemplary embodiment.

[0018] FIGS. 9A and 9B show a container according to an exemplary embodiment.

[0019] FIG. 10 is a container according to an exemplary embodiment.

DETAILED DESCRIPTION

[0020] Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting. [0021] Referring generally to the figures, various metal containers and methods for making the same are shown according to exemplary embodiments. The metal containers disclosed herein may be used to hold food during heating or cooking. In some embodiments, the containers discussed herein are configured for use in a consumer or home-use coffee roasting appliance. The coffee roasting appliance is configured to automatically roast raw or "green" coffee beans in relatively small quantities for home coffee brewing purposes. In operation, a metal container or can containing raw coffee beans is received within a cavity of the coffee roasting appliance. The coffee roasting appliance includes one or more heating elements that deliver heat to the metal can and to the coffee beans in order to roast the coffee beans within the can. The coffee roasting appliance may be configured to rotate the metal can containing coffee beans during roasting. As the can rotates, the beans within the can are agitated helping to ensure even roasting of the beans within the can. When the beans are roasted, the can containing the now roasted beans is opened, and the beans are ground to make coffee from the freshly roasted beans. The metal containers discussed herein are configured to hold raw or unroasted coffee beans and are suitable for holding the beans during roasting using a consumer or counter-top coffee roasting appliance as discussed above. Further, the metal containers discussed herein may be used in other heating or cooking processes, such as a retort process, in which other food items (e.g., vegetables, meats, sauces, fruits, etc.) are cooked within the metal containers.

[0022] Referring to FIG. 1, a metal container or can 10 is shown according to an exemplary embodiment. Can 10 is shown as a three-piece can and includes a sidewall 12. Can 10 includes an open upper end 14 and a lower end 16. Can 10 includes a lower can end wall 18 coupled to sidewall 12 at lower end 16. In FIG. 1, upper end 14 of can 10 is shown before an upper can end is attached to sidewall 12. Can 10 may be shipped from the can manufacturing facility with upper end 14 left open such that can 10 may be filled with raw coffee beans. After can 10 is filled with coffee beans, a can end may be coupled to sidewall 12 at upper end 14 via a double seam to seal the can.

[0023] As shown in FIG. 1, sidewall 12 of can 10 is a tapered sidewall that tapers from upper end 14 toward lower end 16. As such, the diameter of can 10 decreases along the axial length of sidewall 12 from upper end 14 to lower end 16. The taper of sidewall 12 may allow empty cans 10 to be nested to conserve space during the shipment of empty cans 10 to the packing or filling facility. Further, in one embodiment, the cavity of the countertop coffee roasting appliance that receives can 10 may also include a tapered inner surface. In this embodiment, the taper of sidewall 12 matches the tapered inner surface of the cavity such that a can having the

corresponding taper fits securely within the cavity of the roasting appliance. In one embodiment, lower can end 18 may include a vent structure (e.g., one or more holes or apertures through lower can end 18) that allows gases produced during roasting of the coffee beans to escape can 10. In one such embodiment, the vent structure may be a hole or perforation through lower can end 18 that is sealed with a foil or polymer covering. The foil seals the perforation during filing, storing, transport, etc. of can 10. However, the foil seal is adhered such that internal can pressure during roasting will rupture the foil seal allowing gases to escape can 10 during roasting. In another embodiment, lower can end 18 is a solid metal can end configured to hermetically seal the bottom of the sidewall. In such embodiments, lower can end does not include a vent structure or covering foil.

[0024] In the embodiment of FIG. 1, sidewall 12 includes three sections, an upper section 20, a middle section 22 and a lower section 24. Upper section 20 and lower section 24 are substantially cylindrical sections of sidewall 12 with the diameter of lower section 24 being less than the diameter of upper section 20. Middle section 22 extends between the lower end of upper section 20 and the upper end of lower section 24. Middle section 22 is a continuously tapered section. As such, the diameter of can 10 at middle section 22 continuously or smoothly decreases along the axial length of middle section 22 from upper section 20 toward lower section 24. A radially inwardly extending transition section 26 is located at the lower end of middle section 22 and joins middle section 22 to lower section 24.

[0025] Can 10 includes an insert 30. Insert 30 may be made of metal and is supported within can 10. Insert 30 includes an insert body, shown as disc shaped center portion 32 and an upstanding skirt or sidewall 34 that extends upward from the peripheral edge of disc 32. In the embodiment shown in the figures, insert 30 is shaped as a circular cup shaped insert having a cross-section that matches the circular cross-section of can 10. However, insert 30 need not be circular and can be any shape suitable for coupling within a roasting can. In one embodiment, the cross-sectional shape of insert 30 matches the cross-sectional shape of can 10 to provide a relatively tight fit between insert 30 and the inner surface of sidewall 12. For example, if the roasting can is a polygonal prism (e.g., as shown in FIG. 9), the cross-section of insert 30 may also be polygonal.

[0026] As shown in FIG. 1, insert 30 is positioned within can 10 such that insert 30 separates the inner cavity of can 10 into an upper cavity 36 and a lower cavity 38. After filling can 10, upper cavity 36 holds the container contents (e.g., coffee beans, other food, etc.), and lower cavity 38 may hold one or more material which is separated from the coffee beans by insert 30. In one embodiment, lower cavity 38 may include a filter material that filters odor of the coffee during roasting and/or that catches material that is shed from the coffee beans during roasting.

[0027] Insert 30 also includes a pair of upstanding paddles or fingers 40. Fingers 40 act to stir or agitate beans located within can 10 as the coffee roasting appliance rotates can 10 during roasting. The agitation or stirring-action provided by fingers 40 may help to allow for even roasting of the coffee beans within can 10. In one embodiment, fingers 40 extend upward from disc 32 toward upper end 14 and are substantially perpendicular to insert disc 32. Fingers 40 are substantially planar projections including parallel side edges 42 and a curved upper edge 44. In one embodiment, disc 32, sidewall 34 and fingers 40 are formed from a contiguous piece of material. In this embodiment, insert 30 is generally cup shaped with sidewall 34 extending away from disc 32 such that both sidewall 34 and fingers 40 are positioned on the same side of disc 32. In other embodiments, sidewall 34 may extend downward from the peripheral edge of disc 32 such that sidewall 34 and fingers 40 are positioned on opposite sides of disc 32.

[0028] In the embodiment shown, transition section 26 provides a shoulder section having a generally upward facing surface against which the lower surface of insert 30 is seated. In this manner, the upward facing surface of transition section 26 is positioned along sidewall 12 to seat insert 30 properly such that upper cavity 36 and lower cavity 38 are of the desired size. In one exemplary embodiment, the upward facing surface provided by transition section 26 is substantially perpendicular to sidewall 12 and is substantially parallel to a plane defined by lower can end 18. However, it should be understood that the upward facing surface against which insert 30 seats may be angled relative to sidewall 12 at an angle sufficient to support insert 30 at a fixed position along sidewall 12.

[0029] In addition to seating against the upward facing surface of transition 26, insert 30 may be configured to engage sidewall 12 to resist movement relative to sidewall 12. For example, in the embodiment of FIG. 1, the radially outermost surface of insert sidewall 34 engages the inner surface of sidewall 12 forming a friction fit between insert 30 and sidewall 12 sufficient to hold insert 30 in place during transport, filling and use of can 10. In the embodiment shown in FIG. 1, insert sidewall 34 is substantially perpendicular to disc 32. However, in some embodiments, sidewall 34 of insert 30 may be angled outwardly away from disc 32 to increase or optimize the friction fit between insert sidewall 34 and the inner surface of can sidewall 12.

[0030] With sidewall 12 being tapered, the diameter of insert 30 may be selected such that insert 30 engages the sidewall at the desired position along the tapered section of sidewall 12. For example, in one embodiment, the diameter of insert 30 as well as the positioning of transition section 26 are selected to set the relative sizes of upper chamber 36 and lower chamber 38. In various embodiments, the height of lower chamber 38 accounts for less than half of the height of can 10, specifically accounts for less than a third of the height of can 10, and more specifically accounts for less than a quarter of the height of can 10. In various embodiments, transition section 26 is positioned such that less than half of the length of sidewall 12 is below transition section 26, such that less than a third of the length of sidewall 12 is below transition section 26, and more specifically such that less than a quarter of the length of sidewall 12 is below transition section 26.

[0031] Referring to FIG. 2, a view of an exemplary embodiment of can 10 is shown including labeled dimensions as described below. As shown, upper section 20 includes an inner diameter Dl, shoulder 26 includes an inner diameter D2 and an outer radius of curvature Rl, sidewall 12 includes a height HI and lower section 24 includes an inner diameter D3 and a height H2. In various embodiments, Dl is between 2 and 4 inches, specifically is between 2.5 and 3.5 inches, and more specifically is 2.872 inches. In various embodiments, D2 is less than Dl and is between 2 and 4 inches, specifically is between 2 and 3 inches, and more specifically is 2.576 inches. In various embodiments, D3 is less than Dl and is between 2 and 4 inches, specifically is between 2 and 3 inches, and more specifically is 2.578 inches. In various embodiments, HI is between 3.5 and 5.5 inches, specifically is between 4 and 5 inches, and more specifically is 4.520 inches. In various embodiments, H2 is less than one half of HI and is between 0.5 and 2 inches, specifically is between 0.7 and 1.7 inches, and more specifically is 1.197 inches. In various embodiments, Rl is between 0.01 and 0.1 inches, specifically is between 0.03 and 0.09 inches, and more specifically is 0.06 inches. In various embodiments, the dimensions and ranges of dimensions discussed above may be plus or minus a tenth of an inch. In other embodiments, the dimensions and ranges of dimensions discussed above may be plus or minus a half of an inch. FIG. 2 also shows the taper angle A of middle section 22 of sidewall 12. As shown angle A is the angle between the middle section 22 and the longitudinal axis of sidewall 12. In various embodiments, angle A is between 0 degrees and 10 degrees, specifically is between 2 degrees and 8 degrees, and more specifically is between 4 degrees and 6 degrees. In one embodiment, angle A is approximately 5 degrees.

[0032] Referring to FIG. 3A-3D, a schematic representation of the steps of the formation of insert 30 is shown according to an exemplary embodiment, and each FIG. 3A-3D, shows a top plan view and a schematic sectional view of the insert during different steps of formation. As shown in FIG. 3A, a metal disc or slug 50 is provided. As shown in FIG. 3B, a cup 52 is formed from slug 50. During the step shown in FIG. 3B, disc 32 and sidewall 34 of insert 30 are formed. As shown in FIG. 3C, two U-shaped slots 54 are cut into disc 32 forming finger precursor 56. In one embodiment, U-shaped slots 54 may be cut into disc 32 using a press or punch type cutting tool, and in this embodiment, insert 30 may be supported from below to resist downward deformation that may otherwise occur during cutting. As shown in FIG. 3D, finger precursors 56 are pushed upward bending at the edge 60 attached to disc 32 to form fingers 40 and to complete formation of insert 30. As shown in FIG. 3D, after fingers 40 are pushed upward, two apertures 58 through disc 32 are left in the place where finger precursors 56 previously were. In one embodiment, fingers 40 and consequently apertures 58 are sized to be generally smaller than a coffee bean such that coffee beans are maintained in upper cavity 36 and are not permitted to pass through apertures 58. In addition, a screen or mesh material may be positioned over apertures 58 to limit or prevent material located within lower cavity 38 of can 10 from passing into upper chamber 36. In one such embodiment, the screen material may be adhered to the bottom surface of disc 32 extending over apertures 58 after fingers 40 are formed.

[0033] Referring to FIG. 4A-4F, a schematic representation of the steps of the process of making can 10 is shown according to an exemplary embodiment. As noted above, can 10 is a three piece can having a tapered sidewall 12. To form can 10, as shown in the step of FIG. 4A, a rectangular sheet of metal or can blank 70 is provided. As shown in the step of FIG. 4B, can blank 70 is rolled, and the free edges 74 of blank 70 are welded together forming weld 71. When weld 71 is formed, a cylindrical can body 72 is formed from blank 70. As shown in the step of FIG. 4C, cylindrical can body 72 is stretched radially causing the overall length of can body 72 to decrease. During the step shown in FIG. 4C, can body 72 is stretched to form an upper expanded sidewall section 76 and a lower sidewall section 78. In this embodiment, the diameter of upper sidewall section 76 is greater than the diameter of lower sidewall section 78. Further, in addition to stretching, upper flange 80 and lower flange 82 are formed at the upper edge and lower edge, respectively, of can body 72 as shown in FIG. 4C. Upper flange 80 and lower flange 82 are used to form a double seam formed by interlocking and compressing the flanges 80 and 82 with the peripheral edge of the upper and lower can ends, respectively. The double seam couples the can ends to the can sidewall to complete the can and also forms a hermetic seal.

[0034] During the step shown in FIG. 4D, can body 72 is shaped to provide both the tapered sidewall 12 of can 10 and transition section 26. The different diameters of sections 76 and 78 formed in the step of FIG. 4C are specifically selected to facilitate formation of the desired taper of sidewall 12 during the shaping step shown in FIG. 4D. In one embodiment, an expanding mandrel may be used during the step shown in FIG. 4D to form tapered sidewall 12 from can body 72.

[0035] During the step shown in FIG. 4E, lower can end 18 is coupled to sidewall 12 by forming a double seam 83 from lower flange 82 and the peripheral section of material of the lower can end. During the step shown in FIG. 4F, insert 30 is moved through open end 14 and is seated against the upward facing surface of transition 26. In one embodiment, insertion of insert 30 into can 10 may occur at the can manufacturing facility. In another embodiment, insertion of insert 30 into can 10 may occur at the coffee bean packing or filling facility. In this embodiment, one or more cans 10 without an internal insert 30 (e.g., as shown in FIG. 4E) and one or more separate inserts 30 may be shipped to the coffee bean packing facility. Further, as shown in FIG. 5, if can 10 is shipped from the can manufacturer without insert 30 being positioned inside can 10, multiple cans 10 may be nested together. This nesting, when shipping cans 10, may reduce the overall volume of the cans being shipped. FIG. 5 shows the nesting of a first can, shown as can 10' (the outline of can 10' is shown in dashed lines in FIG. 5), inside a second can 10. In the nesting arrangement, inner can 10' seats against transition 26. Thus, transition 26 may facilitate nesting of multiple cans 10 by ensuring sufficient spacing between the lower surface of the lower end wall of the inner can and the upper surface of the lower end wall of the outer can.

[0036] In various embodiments, can 10 may include one or more features configured to engage insert 30 to properly position insert 30 relative to the bottom end wall of can 10 and to help secure insert 30 within can 10. In various embodiments, the feature configured to engage insert 30 is positioned above the lower can end and below the vertical mid-point of sidewall 12 such that the portion of the height of sidewall 12 below the insert is less than half of the height of sidewall 12. For example, as discussed above regarding FIG. 1, transition section 26 includes an upward facing surface against which insert 30 is seated, and the upstanding sidewall 34 of insert 30 provides a friction fit between the outer surface of sidewall 34 and the inner surface of sidewall 12 to secure insert 30 within can 10.

[0037] However, in other embodiments, the upward facing surface against which insert 30 is seated may be provided by a structure other than transition 26, and can 10 may include one or more structures that facilitate the coupling of insert 30 to the inner surface of sidewall 12. For example, as shown in FIG. 6A, sidewall 12 may include a bead 100 formed in sidewall 12. In the embodiment shown, bead 100 is a radially outwardly extending projection formed in the material of sidewall 12. As such, the inner surface of bead 100 is concave relative to the inner surface of sidewall 12. It should be understood that in various embodiments, the beads discussed herein are circumferential beads that extend completely around the sidewall of the can. In this embodiment, a portion of the concave surface of bead 100 is a generally upwardly facing surface against which insert 30 is seated. Further, insert 30 may be shaped to engage bead 100 to help provide for sufficient seating and to help ensure insert 30 remains fixed within can 10. For example, in the embodiment shown in FIG. 6A, sidewall 34 of disc 32 may be angled inward relative to insert 30 and shaped to engage the concave surface of bead 100. In one such embodiment, sidewall 34 of insert 30 may be outwardly curved with the curved sidewall 34 being received within and contacting the concave inner surface of bead 100. In one embodiment, upstanding wall 34 may be resilient and may snap into bead 100 during insertion such that wall 34 engages a portion of the generally downward facing surface of bead 100. With sidewall 34 snap-fitted into bead 100, the contact between sidewall 34 and the downwardly facing surface of bead 100 acts to resist movement of insert 30 toward upper end of can 10 even if can 10 is turned upside down, and thereby acts to hold insert 30 in place within can 10.

[0038] Referring to FIG. 6B, sidewall 12 may include an upper bead 110 and a lower bead 112. In the embodiment shown, both upper bead 110 and lower bead 112 are radially inwardly extending projections formed in the material of sidewall 12 such that inner surfaces of beads 110 and 112 are convex relative to the inner surface of sidewall 12. In this embodiment, a portion of bead 112 provides a generally upward facing surface against which insert 30 is seated against. In this embodiment, upstanding wall 34 of insert 30 provides a friction fit against the inner surface of sidewall 12, and the generally downward facing surface of bead 110 engages the upper edge of upstanding wall 34 to hold insert 30 within can 10 even if can 10 is inverted. In this embodiment, upstanding wall 34 may be resilient such that wall 34 snaps into the region between beads 110 and 112 during insertion. As shown in FIGS. 6A and 6B, in some embodiments, sidewall 12 of can 10 may be a non-tapered sidewall, and one or more beads may be used to provide for sufficient engagement with insert 30. In another embodiment, the can sidewall that includes beads 100, 110 and/or 112 may be tapered.

[0039] Referring to FIG. 6C, a tapered sidewall with transition section 26 may include a radially inwardly extending bead 120. In this embodiment, bead 120 is positioned along sidewall 12 above transition section 26. The lower surface of insert 30 is seated against a generally upwardly facing surface of transition 26. As shown in FIG. 6C, a generally downwardly facing surface of bead 120 engages the upper edge of upstanding wall 34 such that insert 30 is held in place even if can 10 is inverted. [0040] Referring to FIG. 6D and FIG. 6E, in one embodiment, insert 30 may include a plurality of locking lugs 130 extending radially outwardly from insert 30, and a corresponding set of recesses 132 are formed in sidewall 12 or can 10. Locking lugs 130 are engaged or snap- fitted into recesses 132 to couple insert 30 within can 10. In the embodiment shown in FIG. 6D and FIG. 6E, locking lugs 130 extend radially outwardly from the outer surface of sidewall 34 of insert 30. In one embodiment, during insertion of insert 30 into can 10, insert 30 is positioned or rotated such that locking lugs 130 are aligned with recesses 132. While FIG. 6D shows insert 30 with four locking lugs 130, insert 30 may include 3, 5, 6, 7, 8, etc. locking lugs.

[0041] Referring to FIG. 7, in another embodiment, the coffee roasting can may be a two piece can 140 with a tapered sidewall 142. Can 140 is similar to can 10 in many respects, however, can 140 includes a lower end wall 144 that is integral with sidewall 142 (i.e., lower end wall 144 and sidewall 142 are formed from a single contiguous piece of metal). In one embodiment, can 140 includes an insert 30 that is supported within can 140 via a friction fit between the inner surface of sidewall 142 and the outer surface of the upstanding sidewall 34 of insert 30. In other embodiments, can 140 may include any of the insert interface or coupling elements discussed above. In one embodiment, two piece can 140 does not include a polymer coating material affixed to either the outside or the inside surface of the metal of the can, and specifically, in one embodiment, can 140 does not include a polyethylene terephthalate (PET) coating material.

[0042] Referring to FIG. 8 A - 8C, a representation of a process for making can 140 having a tapered sidewall 142 is shown using a draw redraw process. As shown in FIG. 8A, a metal blank is drawn or stretched in a first step in to a partially shaped can body 150. As shown in FIG. 8B, partially shaped can body 150 is stretched or drawn in a second step to form a stretched can body 152. In one embodiment, following stretching, a flange 154 is formed at the upper end of stretched can body 152. As discussed above, flange 154 is interlocked and crimped with a can end to form a double seam sealing the open upper end of stretched can body 152. As shown in FIG. 8C, can 140 is completed from stretched can body 152 by forming beads into the bottom wall 156 of can body 152 to form beaded lower end wall 144. After can 140 is made via the draw redraw process shown in FIG. 8, an insert 30 is inserted into the interior of can 140 as discussed above. In an embodiment in which can 140 does not include a PET coating material, the process for producing can 140 may further include applying one or more lubricant material to the metal material to allow for proper shaping during the draw redraw process. For example, the metal material that is shaped into can 140 may be temporarily coated with a petrolatum material to facilitate shaping of the metal into can 140, and in this embodiment, the petrolatum lubricating material may then be washed or removed from the finished can 140 prior to shipping or filling of can 140.

[0043] FIG. 1 and FIG. 7 each show a coffee roasting can having a tapered sidewall, and as noted above, the tapered sidewall may act to improve friction fit between the upstanding sidewall of the insert and inner surface of the can sidewall, may provide for nesting during shipment of empty containers, and may allow for proper engagement with the cavity of the roasting device. However, in other embodiments, cans of other shapes may be used. In various exemplary embodiments, a coffee roasting can may be shaped as a polygonal prism. In one embodiment, as the can is rotated during roasting, the planar sections of sidewall may facilitate mixing of the coffee beans within the can.

[0044] Referring to FIG. 9A and FIG. 9B, a polygonal prism shaped coffee roasting can, can 160, is shown according to an exemplary embodiment. Can 160 is a hexagonal prism shaped can having circular upper and lower can ends. In one embodiment, the cavity of the roasting appliance may be a polygonal shape to match the polygonal shape of can 160. The matching configuration between the cavity of the roasting appliance and the can may be used to ensure that can 160 is securely engaged by the roasting appliance prior to rotation. Further, a uniquely shaped can 160 that matches the cavity of the roasting appliance may be used to ensure that only the proper type of can is used with the roasting appliance.

[0045] In other embodiments, a coffee roasting can may include a sidewall having a surface feature that engages a mating surface within the cavity of the roasting appliance. Similar to the embodiment discussed above, engagement between the surface feature of the roasting can and the cavity of the roasting appliance may be used to ensure that the proper type of coffee roasting can is used with the roasting appliance. Referring to FIG. 10, an exemplary embodiment of a coffee roasting can 170 having a surface feature is shown. Can 170 includes a recessed, surface feature 172 extending around the sidewall of can 170. In other embodiments, surface feature 172 may include an outwardly projecting feature that extends outward from the sidewall of the can. In the embodiment shown, surface feature 172 is a wave-like pattern including upwardly curved and downwardly curved alternating sections. In other embodiments, surface feature 172 may be other suitable patterns. For example, surface feature 172 may be a saw-toothed pattern or may be a pattern of surface depressions or dimples.

[0046] In various embodiments, the roasting cans and/or cooking cans discussed herein do not include a polymer coating material affixed to either the outside or the inside surface of the metal of the can. Specifically, in various embodiments, the cans discussed herein do not include a polyethylene terephthalate (PET) coating or epoxy coating material. Further, the roasting cans and/or cooking cans discussed herein do not include sealant compound with the double seams joining the can ends to the can sidewall. However, in other embodiments, the cans discussed herein are configured to hold food items (e.g., meats, vegetables, fruits, etc.) during cooking and are intended for consumer purchase at a grocery store. In such embodiments, the cans may include an interior polymer coating material and/or sealant material within the double seams. For cans of this nature, the sealant in the double seam facilitates creation and maintenance of hermetically seal between the can sidewall and cab end wall. Further the polymer coating material provides a barrier between the container contents and the metal of the can.

[0047] While the embodiments of insert 30 discussed above relate primarily to various friction-based couplings between the insert and the inner surface of the sidewall of the container, in other embodiments, other coupling mechanisms may be used. For example, insert 30 may be coupled to the inner surface of the sidewall of the can by a heat stable adhesive material or by a weld or solder.

[0048] In various embodiments, the containers discussed herein may be formed from any material, including metals, plastics, ceramics and glasses. According to an exemplary embodiment, the containers and inserts discussed herein are formed from metal, such as tin- coated steel or aluminum. In some embodiments, the containers and inserts discussed herein are formed from aluminum and the can ends are formed from tin-coated steel. In other embodiments, other metals or materials (e.g., polymers, high-temperature plastic, thermoplastics, cardboard, ceramic, etc.) are used to form some or all of the container.

[0049] Containers discussed herein may include containers of a wide variety of styles, shapes, sizes, etc. For example, the cans discussed herein may be shaped such that cross- sections taken perpendicular to the longitudinal axis of the container are generally circular.

However, in other embodiments the sidewall of the containers, such as can 160 and can 170, discussed herein may be shaped in a variety of ways (e.g., having other non-polygonal cross- sections, as a rectangular prism, a polygonal prism, any number of irregular shapes, etc.) as may be desirable for different applications. In various embodiments, the can sidewall may include one or more axially extending sidewall sections that are curved radially inwardly or outwardly such that the diameter of the can is different at different places along the axial length of the can, and such curved sections may be smooth continuous curved sections. The cans may be of various sizes (e.g., 3 oz., 8 oz., 12 oz., 15 oz., 28 oz, etc.) as desired for a particular application.

[0050] Further, the container ends or can end walls discussed herein may be a variety of suitable walls or closures (e.g., a closure, lid, cap, cover, top, end, can end, sanitary end, "pop- top", "pull top", convenience end, convenience lid, pull-off end, easy open end, "EZO" end, etc.). In an exemplary embodiment, the upper can end may be an "EZO" convenience end, sold under the trademark "Quick Top" by Silgan Containers Corp.

[0051] The separate upper and lower can ends discussed above are shown and/or described coupled to the can body via a "double seam" formed from the interlocked portions of material of the can sidewall and the can end. However, in other embodiments, the can ends discussed herein may be coupled to the sidewall via other mechanisms. For example, can ends may be coupled to the sidewall via welds or solders. In various embodiments, the upper can end may be a closure or lid attached to the body sidewall mechanically (e.g., snap on/off closures, twist on/off closures, tamper-proof closures, snap on/twist off closures, etc.). In another embodiment, the upper can end may be coupled to the container body via an internal vacuum. The container end may be made of metals, such as steel or aluminum, metal foil, plastics, composites, or combinations of these materials. In various embodiments, the can ends, double seams, and sidewall of the container are adapted to maintain a hermetic seal after the container is filled and sealed.

[0052] As discussed above, the containers discussed herein are configured to hold raw coffee beans during roasting using a coffee roasting appliance. It should be understood that the can and insert innovations discussed herein may be utilized in cans configured to hold edible items other than coffee beans. For example, the cans and inserts discussed above may hold nuts, fruits, meats, or vegetables during roasting by a roasting appliance or during cooking in commercial food processing equipment (e.g., a retort). The containers discussed herein may be used to hold perishable materials (e.g., food, drink, pet food, milk-based products, etc.). It should be understood that the phrase "food" used to describe various embodiments of this disclosure may refer to dry food, moist food, powder, liquid, or any other drinkable or edible material, regardless of nutritional value.

[0053] In various embodiments, the cans discussed herein are configured to contain foods at a negative internal pressure (e.g., cans that have an internal vacuum) and the negative internal pressure results in an inwardly directed force on the sidewall of the can. In various

embodiments, the negative internal pressure results from hermetically sealing the can (e.g., via doubled seamed end walls that the top and bottom of the sidewall) while the contents of the can are hot and from the subsequently cooling of the can contents within the hermetically sealed can. In various embodiments, the cans discussed herein are configured to hold contents at an internal vacuum of at least 28 pounds/square inch (gauge) or "psig," and in another embodiment, the cans discussed herein are configured to hold contents at an internal vacuum of at least 22 psig. In other embodiments, the cans discussed herein are filled with food located with the internal cavity of the can and the can is sealed and has an internal vacuum of at least 22 psig, in one

embodiment, and at least 28 psig, in another embodiment.

[0054] In various exemplary embodiments, the relative dimensions, including angles, lengths and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the express dimensions set out in this description.

[0055] Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

[0056] For purposes of this disclosure, the term "coupled" means the joining of two components directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature.

Claims

WHAT IS CLAIMED IS:

1. A metal can for holding food during cooking comprising:

a metal sidewall including an upper end, a lower end and a midpoint, the metal sidewall having an inner surface defining an interior cavity of the can configured to hold food during cooking;

a metal can end coupled to the lower end of the sidewall;

a metal insert located within the interior cavity of the can, the metal insert comprising a planar disc and an upstanding insert sidewall extending from a peripheral edge of the disc portion, wherein a radially outward facing surface of the insert sidewall engages the inner surface of the metal sidewall; and

a circumferential bead formed in the metal sidewall, the circumferential bead located between the lower end and the midpoint of the metal sidewall, the circumferential bead extending radially inward defining a downward facing surface generally facing the lower end of the sidewall;

wherein the insert sidewall includes an upward facing surface generally facing the upper end of the metal sidewall and the upward facing surface of the insert sidewall engages the downward facing surface of the circumferential bead to hold the metal insert below the circumferential bead.

2. The metal can of claim 1 wherein the can end is coupled to the sidewall by a double seam formed from interlocked portions of the material of the sidewall and the can end.

3. The metal can of claim 2 wherein the metal insert is coupled to the inner surface of the sidewall via a friction fit.

4. The metal can of claim 1 wherein the metal insert extends across the interior cavity of the can to engage opposing portions of the inner surface of the sidewall.

5. A metal can for holding coffee beans during roasting comprising:

a metal sidewall including an upper end and a lower end, the metal sidewall having an inner surface defining an interior cavity of the can configured to hold raw coffee beans during roasting;

a can end coupled to the lower end of the sidewall;

wherein at least a portion of the sidewall is tapered between the upper end and lower end of the sidewall.

6. The metal can of claim 5, wherein the can end is coupled to the sidewall by a double seam.

7. The metal can of claim 5, wherein the can end and sidewall are integrally formed from a single piece of metal.

8. The metal can of claim 5, wherein at least a section of the sidewall is polygonal.

9. The metal can of claim 5, wherein the sidewall is round.

10. The metal can of claim 5, wherein the sidewall includes a feature on the outer surface configured to engage with a corresponding structure within a cavity of a coffee roasting appliance.

11. The metal can of claim 10, wherein the feature is at least one of a wave pattern, a saw-tooth pattern and a pattern of dimples formed in the outer surface of the sidewall.

12. The metal can of claim 5, further comprising a cup-shaped insert supported within the interior cavity of the can.

13. The metal can of claim 5, wherein the insert includes a body disc and an upstanding sidewall extending from the peripheral edge of the body disc, and further wherein a friction fit between the outer surface of the insert sidewall and the inner surface of the can sidewall supports the insert within the interior cavity of the can.

14. The metal can of claim 13, wherein the insert includes an agitator finger extending from the body disc of the insert and further wherein the upper edge of the agitator finger is curved.

15. The metal can of claim 13, wherein the insert sidewall is perpendicular to the body disc of the insert.

16. The metal can of claim 13, wherein the insert sidewall is at a non-perpendicular angle relative to the body disc of the insert.

17. The metal can of claim 13, wherein the can sidewall includes a bead formed in the sidewall, wherein the insert engages an inner surface of the bead to support the insert within the interior cavity of the can.

18. The metal can of claim 13, wherein the insert includes a projection extending from the insert sidewall and the inner surface of the can sidewall includes a recess that receives the projection of the insert.

19. The metal can of claim 13, wherein the inner surface of the can sidewall includes an upward facing surface and the insert is seated against the upward facing surface to support the insert within the interior cavity of the can.

20. An stirring insert configured to be coupled to the inner surface of a sidewall of a metal can configured to hold raw coffee beans during roasting, comprising:

a body disc;

a sidewall positioned at the periphery of the body disc and extending away from the body disc; and

a stirring finger extending from the body disc.

21. The insert of claim 20, wherein the stirring finger is integral with the body disc and the sidewall, and further wherein an upper edge of the stirring finger is rounded.

22. The insert of claim 20, wherein the outer surface of the sidewall is configured to form a friction fit engagement with the inner surface of a sidewall of a metal can such that the insert is supported within the interior of the can.

23. The insert of claim 20 further comprising a locking projection extending radially outward from the insert sidewall and configured to engage a recess located along the inner surface of the can sidewall.

24. A method for producing a stirring insert for a coffee roasting can comprising: providing a metal blank;

forming a body disc and an upstanding sidewall from the metal blank, the upstanding sidewall positioned at the peripheral edge of the body disc;

cutting a slot through the body disc, the slot defining the peripheral edge of a stirring finger; and

pushing the stirring finger upward such that the stirring finger extends away from the body disc.

25. The method of claim 24, wherein the slot is cut using a press.

26. The method of claim 25, wherein the body disc is supported during cutting of the slot to resist downward deformation of the body disc during cutting.

27. A method for producing a coffee roasting can comprising:

providing a rectangular metal blank;

forming a cylinder from the metal blank;

shaping the cylinder to form a tapered can sidewall, the sidewall including an open upper end, an open lower end and an upward facing surface located along the inner surface of the sidewall;

coupling an end wall to the lower end of the sidewall; and

inserting a stirring insert through the open upper end of the sidewall such that the insert seats against the upward facing surface of the sidewall.

28. The method of claim 27, wherein shaping includes stretching the cylinder using an expanding mandrel.

29. The method of claim 28, wherein shaping includes radially stretching the cylinder to increase the diameter and decrease the length of the cylinder before stretching using the expanding mandrel.