WO2022235921A1

WO2022235921A1 - Thermal conditioning and material handling method for dislodged frozen beverage contents

Info

Publication number: WO2022235921A1
Application number: PCT/US2022/027855
Authority: WO
Inventors: Matthew P. ROBERTS
Original assignee: Cometeer, Inc.
Priority date: 2021-05-05
Filing date: 2022-05-05
Publication date: 2022-11-10

Abstract

A system and method for providing a loosened liquid frozen beverage content within a receptacle. The method includes filling a receptacle with a liquid content, freezing the content to adhere to the interior of the receptacle, and then a using thermal conditioning and/or material handling to provide an easily dislodged frozen beverage content from the receptacle.

Description

THERM AT, CONDITIONING AND MATERIAL HANDLING METHOD FOR DISLODGED FROZEN BEVERAGE CONTENTS

BACKGROUND

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63/184361, entitled “Thermal Conditioning and Material Handling Method for Dislodged Frozen Beverage Contents”, filed on May 5, 2021, the contents of which are hereby incorporated by reference.

[0002] Frozen concentrate packaging formats are generally inconvenient for preparing fresh beverages. Often, they come in large bulk servings that are messy and need to be thawed before removing them from the packaging. The cylindrical packaging receptacles used for concentrated juice packaging, for example, have removable side walls and removable ends so the consumer does not have to otherwise dislodge the frozen beverage concentrate from the receptacle.

[0003] There is a need for systems and methods for dislodging frozen liquid contents from a single-serve or multiple-serving receptacle, which allows for the easy removal of the frozen liquid contents by the consumer at time of use through an opening in the packaging or a removable lid.

SUMMARY

[0004] Described herein are systems methods for dislodging frozen liquid contents from a single-serve or multiple-serving receptacle to facilitate removal of the frozen liquid contents by the consumer at time of use. In accordance with some aspects, the frozen liquid contents can be removed from the receptacle through an opening in the packaging or a removable lid.

[0005] In one aspect of the present disclosure, a method of producing a receptacle containing frozen liquid contents is described. The method includes providing a receptacle having an interior, introducing a liquid into the interior of the receptacle, freezing the liquid in the interior to produce a frozen liquid contents in the interior, wherein the frozen liquid contents adhere to the receptacle at a first position in the interior, heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents to dislodge the frozen liquid contents from the first position in the interior of the receptacle and moving the receptacle to reposition the dislodged frozen liquid contents in the receptacle.

[0006] In accordance with one aspect, moving the receptacle to reposition the dislodged frozen liquid contents includes repositioning the dislodged frozen liquid contents to a second position in the interior receptacle and allowing the dislodged frozen liquid contents to refreeze and adhere to the interior of the receptacle at the second position.

[0007] In accordance with another aspect, moving the receptacle to reposition the dislodged frozen liquid contents comprises keeping the dislodged frozen liquid contents in motion for a period of time sufficient to allow the dislodged frozen liquid contents to refreeze without adhering to the interior of the receptacle.

[0008] In accordance with some aspects, moving the receptacle includes one or more of flipping, rotating, rocking, whirling, rotary or linear reciprocation, shaking and vibrating.

[0009] In accordance with some aspects, the solid frozen liquid content includes at least one of a frozen coffee extract, a frozen tea extract, a frozen lemonade concentrate, a frozen vegetable concentrate, a frozen broth, a frozen liquid dairy product, a frozen alcohol-based product, a frozen concentrated soup, a frozen syrup, a frozen fruit concentrate, a vitamin water, and a nutraceutical mixture.

[0010] In accordance with some aspects, freezing the liquid in the interior to produce a frozen liquid contents comprises freezing the frozen liquid contents to a temperature at least 10 degrees F below a freezing point of the frozen liquid contents.

[0011] In accordance with some aspects, freezing the frozen liquid contents comprises the use of one or more of dry ice, liquid nitrogen, liquid carbon dioxide, liquid helium, ammonia, freon, and freon substitutes.

[0012] In accordance with some aspects, heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents comprises heating the receptacle.

[0013] In accordance with some aspects, heating the receptacle comprises providing a heated fluid proximate to an exterior surface of the receptacle.

[0014] In accordance with some aspects, heating the receptacle includes applying heat to the receptacle from a heat source selected from the group consisting of hot air, a heated liquid, steam, microwave energy, IR radiation, radio frequency heating, an applied (contact) heated surface and combination thereof.

[0015] In accordance with some aspects, the receptacle includes a cup-like body and a closure disposed over the body sealing the receptacle and defining the interior of the receptacle. In accordance with some aspects, the closure comprises a removable lid. In accordance with some aspects, the cup-like body comprises a hemispherical shaped body.

[0016] In accordance with some aspects, the receptacle includes a sidewall extending from a first end of the receptacle to a second end of the receptacle, at least a portion of the sidewall being tapered; a continuous end layer disposed at the first end of the receptacle, the continuous end layer transitioning from the sidewall at a boundary between the sidewall and the continuous end layer, the boundary encompassing the continuous end layer, the continuous end layer lacking openings within the continuous end layer encompassed by the boundary, and the continuous end layer defining an unbroken inner surface and a corresponding unbroken outer surface; a closure disposed at the second end of the receptacle, the sidewall, the continuous end layer, and the closure defining the interior of the receptacle.

[0017] In accordance with some aspects, the method further includes sealing the receptacle prior to introducing the liquid into the interior of the receptacle, wherein the liquid is introduced to the interior of the receptacle through an inlet in the receptacle.

[0018] In accordance with some aspects, the method further includes sealing the receptacle after introducing the liquid into the interior of the receptacle.

[0019] In accordance with some aspects, the receptacle is made of aluminum.

[0020] In accordance with some aspects, at least one of freezing the liquid in the interior to produce a frozen liquid contents in the interior, heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents, and moving the receptacle to reposition the dislodged frozen liquid contents occurs while the receptacle moves along a conveyor.

[0021] In accordance with another embodiment, a method of producing a receptacle containing frozen liquid contents is described. The method includes providing a receptacle having an interior containing frozen liquid contents in the interior, wherein the frozen liquid contents adhere to the receptacle at a first position in the interior, heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents to dislodge the frozen liquid contents to dislodge the frozen liquid contents from the first position in the interior of the receptacle, and moving the receptacle to reposition the dislodged frozen liquid contents in the receptacle.

[0022] In some aspects, moving the receptacle to reposition the dislodged frozen liquid contents comprises repositioning the dislodged frozen liquid contents to a second position in the interior receptacle and allowing the dislodged frozen liquid contents to refreeze and adhere to the interior of the receptacle at the second position.

[0023] In other aspects, moving the receptacle to reposition the dislodged frozen liquid contents comprises keeping the dislodged frozen liquid contents in motion for a period of time sufficient to allow the dislodged frozen liquid contents to refreeze without adhering to the interior of the receptacle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Various features and advantages of the disclosed techniques can be more fully appreciated with reference to the following detailed description of the disclosed subject matter when considered in connection with the following drawings, in which like reference numerals identify like elements.

[0025] FIGS. 1A-1G illustrate various embodiments of receptacle geometries and frozen liquid contents configured in different forms and packaged to facilitate release of the frozen liquid contents from the receptacle, according to some embodiments of the invention.

[0026] FIGS. 2A-2C illustrate various embodiments showing how a liquid may be introduced to the receptacle after the lid or closure is in place, according to some embodiments of the invention.

[0027] FIG. 3 illustrates a range of exemplary packaging options and receptacle shapes that could be accommodated by a machine-based apparatus, according to some embodiments of the invention.

[0028] FIG. 4A illustrates a side cross-sectional view of a receptacle with frozen liquid contents at a first position, according to some embodiments of the invention.

[0029] FIG. 4B illustrates a side cross-sectional view of a receptacle with a dislodged frozen liquid contents, according to some embodiments of the invention.

[0030] FIG. 5 illustrates a side cross-sectional view of a receptacle, according to some embodiments.

DETAILED DESCRIPTION

[0031] In the following description, numerous specific details are set forth regarding the systems and methods of the disclosed subject matter and the environment in which such systems and methods may operate to provide a thorough understanding of the disclosed subject matter. It will be apparent to one skilled in the art, however, that the disclosed subject matter may be practiced without such specific details, and that certain features, which are well known in the art, are not described in detail to avoid complication of the disclosed subject matter. In addition, it will be understood that the embodiments described below are exemplary, and that it is contemplated that there are other systems and methods that are within the scope of the disclosed subject matter.

[0032] The various techniques described herein provide for the packaging of one or more frozen foods or beverage liquids and how to efficiently convert this frozen liquid contents into a high quality, tasty food or beverage product. The single chamber receptacle can be designed such that a user can remove the frozen liquid contents to conveniently produce a consumable liquid beverage or food product directly therefrom with a desired flavor, potency, volume, temperature, and texture in a timely manner without the need of brewing. Typically, the receptacle is filterless. For simplicity, a frozen food or beverage liquid may be referred to as the “frozen liquid contents” or “frozen liquid content”. As used herein, the frozen liquid contents may alternatively be referred to as a "puck".

[0033] In some embodiments, the liquid that is frozen to create the frozen liquid content may be any frozen liquid matter, which in some embodiments can be derived from a so-called extract, e.g., a product obtained through the removal of certain dissolvable solids using a solvent. For example, the extract may be created using water to remove certain desirable dissolvable solids from coffee grounds or tea leaves. Somewhat confusingly, certain liquid extracts with a high-solids content are often referred to as a concentrated extract. The use of the term “concentrated” in this context may or may not be entirely accurate depending on whether the high solids content was achieved purely through solvent extraction of the solids using a limited amount of solvent to ensure a high level of dissolved solids as-made, or through a secondary step of concentration wherein solvent was removed from the liquid by some technique and/or process, for example, by reverse osmosis or evaporation using heat or refrigeration, to increase its potency or strength. The former example is a high-solids extract; the second example is a concentrate.

[0034] The liquid used to make the frozen liquid content may also be a pure concentrate, e.g., a product obtained only by removing water or another solvent from a consumable compound such as a fruit juice or a soup, to create a fruit juice concentrate or a broth concentrate. In some embodiments, water may be removed from milk to create condensed milk. High TDS values and/or concentrations may be desirable either to reduce transportation costs and shelf space, or for convenience, for potency and serving size versatility of created products via dilution, or for enhanced shelf life due, for example, to enhanced anti-microbial activity due to reduced water activity. These specifics are intended to exemplify variation, but any liquid food or beverage product, regardless of how it is created, and regardless of its solids content falls within the scope of the present disclosure.

[0035] Although the present disclosure is primarily directed to the preparation of receptacles containing frozen liquid contents for opening manually by the end use consumer, the receptacles can also be used with machine-based dispensing systems to facilitate the melting and/or diluting of the frozen liquid contents and creation of a ready - to-consume food or beverage therefrom. Examples of various devices useful in producing melted food or beverages using receptacles such as those disclosed herein are provided in U.S. Pat. Nos. 9,408,493; 9,468,230; 9,630,770; 9,538,877; 9,516,970 and 10,314,320, the contents of which are hereby incorporated by reference.

[0036] FIGS. 1A-1E show various embodiments of how the frozen liquid contents may be structured and packaged to allow for a easy removal of the frozen liquid contents from the receptacle. Within the receptacle, the frozen liquid contents may be frozen into any useful shape or size.

[0037] FIG. 1 A provides a section view of receptacle 110, (without a sealing lid in place), wherein the receptacle defines an interior or cavity for packaging of the frozen liquid contents 120. The frozen liquid contents 120 can be frozen in-place by filling the receptacle with a liquid and then freezing the liquid, or the frozen contents can be frozen into a shape and then placed in the receptacle. In this instance, the frozen liquid contents are shown displaced away from the bottom portion of the receptacle to allow for easy removal from the receptacle to produce a beverage of a desired flavor, strength, volume, texture and temperature.

[0038] FIG. IB illustrates another embodiment, wherein the frozen liquid contents have been molded to a shape configured to match the outside of the receptacle and subsequently loaded, such that the pre-molded shape defines a through-hole 130 in its body and a relief portion 132 below for facilitating removal from the receptacle.

[0039] FIG. 1C shows a plurality of frozen liquid content pieces 140-180 provided in multiple and various shapes and sizes, with large interstitial spaces to provide for easy removal from the receptacle. In some embodiments, the frozen liquid contents within the sealed receptacle may include a plurality of concentrates and compositions. For example, frozen liquid contents 140 and 150 could comprise a lemonade concentrate, while frozen beverage concentrates 160, 170, and 180 may comprise a tea concentrate, resulting in an “Arnold Palmer”.

[0040] FIGS. ID and IE illustrate an embodiment for an alternatively shaped receptacle 115 that includes a bottom portion having a dome 195 (bistable or otherwise). In FIG. ID the receptacle 115 is shown in its initial condition when the frozen liquid contents are added and frozen in place, complete with a frozen dome structure 195 in the bottom, with the dome structure in a primary or initial position, distended outwardly from the receptacle. FIG. IE shows the condition of the receptacle 115 after the dome 195 has been displaced to a secondary position directed inward into the cavity of the receptacle such that the liquid frozen liquid contents 190 are displaced upwardly, into the headspace, reverting or “exchanging” the space or void between the inside bottom of the receptacle and the bottom portion of the frozen liquid contents. This displacement desirably creates a space for easy removal of the frozen liquid contents from the receptacle.

[0041] FIG. IF illustrates a receptacle 196 comprising a multi-faceted shape. In this embodiment, the receptacle 196 includes different shape portions 196A-E. In some embodiments, the process of filling, heating and dispensing a frozen liquid content may be generally unaffected by the size or shape of the receptacle. In some embodiments, certain design considerations can be considered regarding using geometries that may, for example, promote and facilitate unrestricted release of the frozen liquid contents, and/or the like. For example, one or more of such design considerations can be met with positive (non-locking) draft in the sidewalls of the receptacle where it is in contact with the frozen liquid contents. Draft can be achieved by, for example, tapering the sidewalls of the receptacle, such as tapering the sidewalls outward from bottom of the receptacle to top of the receptacle (e.g., the diameter of the receptacle gets larger nearer the top of the receptacle). This can create a positive draft such that pushing the frozen liquid contents away from the bottom of the receptacle creates clearance around the sides of the frozen liquid contents (e.g., which avoids mechanical locking of the frozen liquid contents against the sides of the receptacle). Such positive draft can be used to create a natural flow path for release of the frozen liquid contents from the receptacle.

[0042] FIG. 1G illustrates a receptacle 197 with a lid 198 that includes a pull tab 199 that may be removed by the consumer. The pull tab 199 can be removed to facilitate use of a straw or similar device in combination with the receptacle 197. As another example, the pull tab 199 can be removed to facilitate introduction of diluting fluids into the receptacle 197 or release of the frozen liquid contents from the receptacle.

[0043] FIG. 2A illustrates a perspective view of the receptacle, including a formed seal closure such as a lid structure 118, which may include a puncture 210 therein, whereby, in some embodiments, a fluid, such as the liquid contents, can be introduced into the receptacle. The lid structure 118 can include a tab 119 for allowing manual removal of the lid to access the frozen liquid contents without a need for perforation of the lid in certain instances. This lid structure can be made from the same material as the receptacle to better support efforts toward single-stream recycling. The lid structure can be made of sufficient gage thickness to adequately withstand internal pressure created during manufacture . For example, a vibratory, centrifugal, or rotation platform or the like that facilitates repositioning of the frozen liquid contents can affect the pressure put on the lid, seal, and receptacle. The lid may be attached to the receptacle by any suitable means such as, for example, heat sealing or crimping, radial folding, sonic welding, and the function can be achieved by any mechanism or form of the lid that seals the internal cavity and acts as a barrier against gas or moisture migration.

[0044] FIG. 2B shows an alternative embodiment of a lid including two openings 215. FIG. 2C illustrates another embodiment showing a receptacle 270 closed with lid 250. The frozen liquid contents (not shown) are frozen within the domed bottom of the receptacle. The puck may flow out of the receptacle into a secondary receptacle for consumption.

[0045] In some embodiments, the frozen liquid contents contained in these receptacles can be better preserved when deaerated, or deoxygenated, including use of deaerated or deoxygenated solvents (e.g., water) during an extraction process when appropriate. In some embodiments, the liquid used to make the frozen liquid contents may be frozen at a time of peak quality in terms of freshness, flavor, taste and nutrition. In some embodiments, such as for a coffee-based beverage, the frozen liquid content is flash-frozen during the period of peak flavor immediately following extraction to preserve the optimum taste, aroma and overall quality and thereafter distributed in a frozen state for preserving taste and aroma thereof. For example, an espresso concentrate may be preserved and may taste best when it is ground within 0-36 hours following roasting, brewed immediately after grinding, and using deoxygenated water during the brewing process. By flash freezing the liquid concentrate, extract, or other consumable fluid during this period of peak flavor immediately following brewing, it is possible to capture the peak flavor, optimum taste, aroma and overall quality of the extract. Further, by packaging this flash frozen liquid in a gas impermeable and recyclable receptacle using MAP techniques (as described further herein), and providing the frozen liquid contents are maintained in a frozen state during subsequent storage and delivery to the final consumer, the fresh flavor can be maintained almost indefinitely. In some embodiments, the frozen liquid content may be frozen by removing heat from a selected and controlled portion of the receptacle so as to later facilitate dislodging the bonds (adhesion) created between the frozen liquid content and the sides of the receptacle. For example, in certain embodiments, a liquid content is placed in a receptacle, and heat is removed so as to cause the liquid to freeze starting at the top surface of the liquid and then to freeze downward. Doing so reduces the adhesion between the frozen liquid content and the interior of the sidewalls of the receptacle.

[0046] In some embodiments the packaging may be distributed above freezing if the quality of the content can be maintained by some other FDA food safe method e.g., a syrup used to make carbonated beverages. In some embodiments, the frozen liquid contents may be frozen and never melted, melted once or numerous times during distribution. Distributing and maintaining the receptacles at a temperature below the freezing point of the frozen liquid contents may increase aspects of quality preservation and nutrient-rich food safety, but is not required for all embodiments. In some embodiments, the beverage concentrate is flash-frozen and kept frozen in its receptacle until it is ready to be melted and/or diluted immediately prior to being prepared for consumption.

[0047] In some embodiments the frozen liquid content can also be packaged as a plurality of frozen liquid contents, configured in a layered and/or blended format. In some embodiments, the frozen liquid contents can be configured in any shape or multiple geometric shapes so long as the contents will fit within the cavity volume of the receptacle while maintaining an unfilled region and are capable of being repositioned for certain puncture implementations by an accommodating system. In some embodiments, the frozen liquid contents may be crushed or macerated to increase the surface area of the frozen liquid contents to increase melting rates.

[0048] In some embodiments the liquid comprising the frozen liquid content may be frozen after it has been measured into the receptacle. In some embodiments the fluid used to create the frozen liquid content may be frozen prior to delivery to the receptacle, e.g., pre-frozen in a mold, extruded, frozen and cut to size, or by other means and then deposited in the receptacle as a frozen solid of some desirable shape. This may be done in cooperation with the dimensions of a receptacle with a tapered portion such that the frozen liquid content does not interfere with areas of the receptacle designated for puncture. For example, the frozen liquid content can be shaped so as to be displaced away from certain areas because its diameter is larger than that of a top, bottom, or other first or second end of a receptacle, as shown in FIG. 1 A. Stated another way, the frozen liquid contents may be created in a first phase or separate step, and then received, inserted and sealed in a receptacle. In some embodiments the liquid beverage concentrate is received as a slurry or liquid, to be frozen, and sealed in the receptacle in turn, or in unison. In some embodiments the frozen liquid contents are of a potency, shape and size, and are structured within a receptacle such that a machine-based system can easily melt and/or dilute the liquid frozen liquid contents, converting the contents to a consumable liquid of a desired flavor, potency, volume, temperature, and texture.

[0049] In some embodiments the receptacle for holding/storing the frozen liquid contents using the techniques described herein includes a cup-shaped portion having a continuous and closed bottom portion, a continuous sidewall extending from the bottom portion, and a sealable top opening defined by a continuous sidewall that tapers outwardly as it extends away from the bottom portion. The wall is uninterrupted by filters or other internal features that would interfere with certain puncture, frozen liquid content displacement and flow implementations.

[0050] In some embodiments, the receptacle includes a cavity for storing the frozen liquid content. The packaging in which the frozen liquid contents are sealed, before and hereinafter referred to as a “receptacle” could otherwise be described as a cartridge, a cup, a package, a pouch, a pod, a container, a capsule or the like. The receptacle can be in any shape, styling, color or composition, and may be styled to enhance the liquefaction environment in cooperation with the dispensing apparatus. The packaging may be flexible, have a definitive shape, or combination thereof. For aesthetic or functional reasons, for example, to compliment pod detection or motion drive functions applied to the pod, the walls of the receptacle may be concave and/or convex to provide for different pod sizes while keeping certain interfacing dimensions constant.

[0051] In some embodiments, the receptacle includes a closure for sealing the receptacle to assist in maintaining a MAP gas environment. In this case, a hermetic seal formed between a lid and the receptacle may be accomplished using a variety of methods, including, but not limited to a patch, glue, cork, heat seal, crimp, and/or the like. In some embodiments, the closure may be designed to be manually removable, e.g., with a pull tab on a lid as previously noted.

[0052] The frozen liquid contents may be packaged in a material that provides control of gas migration, e.g., the receptacle may be comprised of a gas impermeable material for creating a long lasting storage package for preserving freshness and aroma of the packaged frozen liquid contents. For example, the receptacle may be comprised of an aluminum substrate or other metal material and typically prepared with a coating approved by the FDA for contact with food, if needed. As another example (e.g., if recyclability is not a critical concern), the receptacle may be comprised of a multi-layer barrier film including, for example, a layer of EVOH plastic. In some embodiments, if the receptacle is fabricated from a metal, the receptacle will preferably be made from a highly thermally conductive material such as aluminum and thereby be supportive of faster heat transfer. In some embodiments the packaging may include edible packaging materials that may be dissolved and consumed. In some embodiments the receptacle and its closure are comprised of a gas impermeable, recyclable material such that a spent receptacle, including the closure and other packaging features, can be recycled in its entirety

[0053] In some embodiments, the frozen liquid contents is packaged with headspace, with no headspace or limited headspace. Headspace refers to any excess atmosphere within a sealed receptacle, which, optionally, is located between a top portion of the frozen liquid contents and the lid or closure portion of the receptacle. Furthermore, any headspace in the packaging receptacle may be advantageously filled using a MAP gas, such as argon, carbon dioxide, nitrogen, or another gaseous compound which is known to be less chemically active than air or oxygen. In some embodiments the top or outermost layer or envelope of the frozen liquid contents may be layered with a frozen, deaerated coating of water which may act as a preservative barrier. In some embodiments the frozen liquid contents are vacuum sealed in a flexible receptacle. In some embodiments the frozen liquid contents are packaged in a receptacle in a manner that minimizes the surface area contact of contents with the atmosphere, especially oxygen gas, but also any gas that carries off aroma.

[0054] In some embodiments the receptacle is coated on the inside with a material that significantly reduces the force needed to dislodge the frozen liquid contents from the sides or bottom of the receptacle to facilitate movement of the frozen liquid contents. In some embodiments the bottom of the receptacle incorporates a dome structure (bistable or otherwise) which can be distended downward, away from the bottom of the receptacle during filling and freezing of the liquid contents and subsequently inverted upward to a its second stable position after freezing to hold the frozen liquid contents away from the bottom of the receptacle. In some embodiments the dome is inverted at the factory prior to shipment of the product to consumers. In some embodiments the dome is inverted by the consumer immediately prior to use. These embodiments are merely examples and not cited to limit the functions or features of the receptacle that may facilitate dislodging frozen liquid contents or beverage creation. Moreover, in the example above, the frozen liquid content is displaced upward into a headspace by the dome. However, in other embodiments, the frozen liquid content can be displaced in a different direction (e.g., downward or sideways) into an unfilled region of the receptacle and remain within the scope of the invention. Similarly, the frozen liquid content can be of a shape and size to facilitate fracture by a needle penetrating the bottom or top of the receptacle.

[0055] In some embodiments the packaging of the frozen liquid contents includes additional barriers or secondary packaging that protects the frozen concentrates from melting or exposure to ultraviolet light during distribution. For example, packaging frozen liquid contents in a receptacle that is further packaged within a cardboard box adds a layer of insulation and would thereby slow temperature loss or melting of the frozen liquid contents, e.g., when such temperature loss or melting is undesirable.

[0056] In embodiments of the present techniques, the method disclosed herein for creating a food or beverage from frozen liquid contents advantageously includes a receptacle that is filterless, as distinguishable from the filtered receptacles currently available, as exemplified, for example, by US Patent No. 5,325,765, among other filtered beverage receptacles. A filterless receptacle, and, for example, (1) the (virtually) complete removal of the frozen liquid contents during subsequent delivery and (2) the use of a homogeneous material of construction, renders the receptacle ideally suited for recycling.

[0057] In some embodiments, a secondary receptacle used to collect the melted/diluted contents may include any receptacle known to hold liquid food or beverages. This secondary receptacle could be a container, thermos, mug, cup, tumbler, bowl, and/or the like. This secondary receptacle may or may not be included in the secondary packaging. Note: an example of this would be a consumer package with a soup bowl containing instant rice or noodles sold along with a receptacle of frozen liquid broth concentrate that combines to make a bowl of soup after the frozen liquid contents are melted and/or diluted and discharged into the secondary packaging. Alternatively, the secondary receptacle may be separately provided by the consumer.

[0058] In some embodiments, the consumer may desire a beverage with no dilution of the frozen liquid contents e.g., the frozen liquid contents are already at the correct flavor, volume and potency. For example, the frozen liquid contents may already be at a desired TDS level for consumption, e.g., an espresso, or hot fudge sauce and need to only be melted and dispensed at the desired temperature and texture. For example, the machine-based system may melt the frozen liquid contents by putting a thermally conductive receptacle against a coil heater or by irradiating it with infrared light or by impinging a heated gas or steam against the outside of the receptacle and then puncturing the receptacle after the contents reach a desired temperature. Furthermore, the frozen liquid contents may be conveniently dispensed from the machine-based system into a subsequent container. In some examples, the lid is removed prior to or after melting and heating for direct consumption from the receptacle.

[0059] FIG. 3 illustrates a range of receptacle sizes and shapes (310, 320, 330, and 340) that could be used in accordance with various aspects of the present disclosure. It will be recognized by one skilled in the art that the process of filling, melting and diluting a frozen liquid content may be, in some embodiments, generally unaffected by the size or shape of the receptacle.

[0060] The thawing and displacement system, used after the liquid contents are initially frozen, may use any source of heat, motion, or a combination thereof to expedite the thawing or liquefaction of at least a portion of a surface layer of the frozen liquid contents. Therefore, the thawing system may include various sources of heat and/or motion. Electromagnetic radiation, a heated coil, hot air, a thermo-electric plate, a heated liquid bath, steam and the like are all examples of possible sources of heat that may expedite the rate of thawing of the surface layer of the puck. In addition, motion may be introduced using a centrifuge, rotational, rocking, rotary or linear reciprocation, including agitation both back and forth or up and down or a vibration platform or the like as a means of expediting the thawing rate. One skilled in the art, however, will recognize that various other physical action principles and mechanisms therefore can be used to expedite thawing or liquefaction of a surface layer of the frozen liquid contents. As described herein, manual or automatic (electronic) machine-based methods can be used to expedite the partial thawing and an increase in temperature of the frozen liquid contents using various forms of motion, electric frequency / electromagnetic energy, and/or heat.

[0061] FIG. 4A illustrates a side cross-section view of a receptacle 400 with a frozen liquid contents 415 positioned at an end layer 410 of the receptacle 400. FIG. 4B illustrates a side cross-sectional view of the receptacle 1400 with the frozen liquid contents 415 displaced away from the end layer by flipping the recptacle 400 over such that the frozen liquid contents are at a second position.

[0062] Any of the receptacle embodiments disclosed herein can, optionally, possess a coating on the inner surface of the mixing chamber formed by the receptacle to promote ease of release of the frozen liquid content from the inner surface. Considerations for selection of the coating include that the coating must be food safe and not exhibit unacceptable levels of chemical leaching into the frozen liquid contents during storage or into the product during the melting and/or diluting process. Similarly, it must not absorb desirable flavor and aroma compounds or oils from the frozen contents, especially during filling and dispensing operations when the contents are in liquid form. Other factors include that the coating must have a favorable coefficient of static friction, porosity measure, and surface roughness measure so as to reduce the force required to release the frozen liquid contents from the receptacle relative to an uncoated surface. The coating must maintain the aforesaid desirable characteristics under the temperature range to which the receptacle will be exposed ( e.g ., about -20°F to about 212°F.) In some embodiments, the coefficient of static friction of the coating ranges from 0.05 to 0.7. In other embodiments, the coefficient of static friction of the coating ranges from 0.3 to 0.4. In other embodiments, the coefficient of static friction of the coating ranges from 0.1 to 0.2. In other embodiments, the coefficient of static friction of the coating ranges from 0.05 to 0.1. In other embodiments, the coefficient of static friction of the coating ranges from 0.08 to 0.3. In other embodiments, the coefficient of static friction of the coating ranges from 0.07 to 0.4. In other embodiments, the coefficient of static friction of the coating ranges from 0.1 to 0.7. In some embodiments, the coating includes one or more of polypropylene, ultra-high-molecular-weight polyethylene, polytetrafluoroethylene, fluorinated ethylene propylene, high-density polyethylene, low-density polyethylene and/or mixtures and/or co-polymers of these materials, e.g, polypropylene/polyethylene mixture.

[0063] Embodiments of the invention may also include tapered cylindrical receptacles having a profile similar to that of receptacle 500 shown in FIG. 5 and having heights ranging from 1.65 inches to 1.80 inches, top inner diameters (Top ID) ranging from 1.65 inches to 2.00 inches, draft angles ranging from 1.5 to 6 degrees, and bottom inner diameters (Bottom ID) ranging from 1.30 inches to 1.75 inches (while maintaining the draft angle within the recited range.) In certain embodiments, the height ranges from 1.70 inches to 1.75 inches, the Top ID ranges from 1.70 inches to 1.95 inches, the draft angle ranges from 1.5 to 6 degrees, and the Bottom ID ranges from 1.35 inches to 1.70 inches (while maintaining the draft angle within the recited range.) In other embodiments, the height ranges from 1.65 inches to 1.80 inches, the Top ID ranges from 1.75 inches to 1.90 inches, the draft angle ranges from 1.5 to 6 degrees, and the Bottom ID ranges from 1.40 inches to 1.65 inches (while maintaining the draft angle within the recited range.) In still further embodiments, the height ranges from 1.65 inches to 1.80 inches, the Top ID ranges from 1.80 inches to 1.90 inches, the draft angle ranges from 1.5 to 6 degrees, and the Bottom ID ranges from 1.45 inches to 1.60 inches (while maintaining the draft angle within the recited range.) In one embodiment, the height is about 1.72 inches, the Top ID is about 1.80 inches, the draft angle is about 5 degrees, and the Bottom ID is about 1.45 inches. Other ranges of these parameters are within the scope of the invention.

[0064] The present disclosure contemplates an understanding of different compounds within a frozen beverage extract or concentrate, and their impact on thermal properties. The thermal properties of frozen water, for example, are fairly straight forward. In a pure liquid format, it takes 0.5 calories of heat/energy to raise the temperature of one gram of ice one degree Celsius. Once ice hits 0° Celsius, it then takes 80 calories of heat to actually liquify one gram of ice. The energy to melt ice is known as the latent heat of fusion. Once water is liquified, it takes 1.0 calorie to heat one gram of water one degree Celsius.

[0065] The level of certain compounds or additives dissolved within a liquid, which forms a beverage concentrate or extract, normally decreases all of these numbers.

[0066] Knowledge of the thermodynamics of the composition allows beneficial use of directed energy as will be described below to achieve certain beneficial purposes that add convenience to the user experience in dispensing the frozen contents of some receptacles. The thermodynamics of a specific solution can be calculated and the information obtained can be instructive in the present disclosure. As an example, by utilizing the thermodynamic properties of a frozen beverage contents and it's packaging, one can freeze and then loosen the frozen beverage contents inside its packaging via thermal conditioning.

[0067] When trying to thermally condition a frozen liquid content (puck) within a receptacle the heat transfer rate, thickness, and conductivity of the receptacle affect one's ability to properly control the freezing, liquefication, or heating of the beverage contents. For example, aluminum has a high thermal conductivity rate and aluminum beverage packaging has a relatively low thermal mass. This makes it a great candidate for controlling the freezing and melting of a puck. Aluminum has a conductivity rate of 205 W/m K, which is significantly greater than ice with a rate of 1.6 W/m K.

[0068] In accordance with one aspect, a method and system for creating a loosened beverage contents (puck) within a receptacle is disclosed. The steps for creating a frozen loosened beverage content (loosened puck) within a receptacle include filling a receptacle with a liquid and freezing it to cause the frozen liquid to adhere to the receptable and to reach a specific internal temperature below the freezing point of the beverage content. In accordance with certain aspects, the puck is frozen to an internal temperature of at least 10 °F below the freezing point of the beverage content. In certain aspects, the puck is frozen to an internal temperature from about 50 °F to 10 °F, more particularly from about 40 °F to 10 °F, and still more particularly from about 30 °F to 15 °F below the freezing point of the beverage content.

[0069] In accordance with some aspects, heat is applied to the outside of the receptacle to dislodge the frozen liquid content from the internal walls of the receptacle by melting a portion (a thin interfacing layer) of the frozen liquid content. In accordance with other aspects, the disclosed method further includes flipping or agitating the receptacle for some period of time to move the frozen liquid content from a first position to a second position or a series of different positions within the receptacle. A subsequent step includes allowing the core temperature of the still frozen beverage contents to refreeze the liquefied portion in a specific new position or, with some extended period of agitation, to keep the frozen liquid content from being lodged (reattached to the internal wall) within the receptable.

[0070] The present disclosure also provides a method and system for creating a loosened beverage contents within a receptacle intended to facilitate the easy removal of the frozen contents (puck) by a consumer at time of use. Such a pre-loosening of the puck greatly improves the convenience of dispensing the frozen puck and improves the overall user experience. In some embodiments, a liquid beverage content is dispensed into a receptacle that has a bottom, tapered side walls and lid. In some embodiments, the liquid beverage content is frozen within the receptacle such that it creates a puck which adheres to the bottom and portions of the sidewalls of the receptable. In some embodiments, this frozen puck is further cooled below its freezing point such that there is a "reserve of coldness" that can be subsequently used to refreeze a thin portion of the outer layer of the puck which might be thawed, the process of refreezing being done without any additional external cooling effort. In some embodiments, the receptacle for the frozen beverage content is positioned or moved such that the frozen liquid content may be more easily dislodged from the receptacle bottom or walls if a portion of the surface layer of the frozen contents (puck) is thawed.

[0071] In some embodiments, heat is subsequently applied to the outside of the receptacle. In some embodiments, the heat transfer rate through the sidewalls and bottom of the receptacle is significantly higher than the heat transfer rate through the frozen contents, causing a thin surface layer of the frozen contents to thaw and liquify without causing more inner portions or the core of the frozen contents to thaw. In some embodiments, this thawing/partial liquification of the surface layer of the frozen contents allows it to easily dislodge from the wall, bottom, and/or lid of the receptacle. In some embodiments, the external heat is stopped once sufficient heat has been added to the receptacle to dislodge the frozen contents and thereafter the still-frozen portion of the puck can use its "reserve of coldness" to refreeze the partially melted surface layer of the puck. In some embodiments, this refreezing occurs once the frozen puck has been repositioned into a fixed location that is more advantageous for subsequent removal of the contents by a consumer. In some embodiments, the puck is kept in continuous motion while the refreezing occurs such that it does not re-adhere to the sidewalls or bottom of the receptacle and remains free to rattle around inside the receptacle and easily fall out of the receptacle once the lid of the receptacle has been removed.

[0072] In some embodiments, the frozen liquid contents may include any edible liquid including, but not limited to, coffees, teas, juices, alcoholic or non-alcoholic beverages, soups, pharmaceuticals, nutraceuticals, or combination thereof.

[0073] In some embodiments, the receptacle may be shaped as described above with a bottom, tapered sidewalls, and a lid. In some embodiments, the cup may be shaped as a hemisphere, i.e., with a spherical bottom and a flat lid section. In some embodiments, the receptacle shape is some combination of the two. In some embodiments, the liquid content is frozen or preformed prior to putting it into the receptacle. In some embodiments, the receptacle may be filled via a special inlet to the interior of the receptable such that a lid does not have to be subsequently attached or installed. In some embodiments, the receptable may be of any known packaging format used to package food or beverage material, and include any shape or size. In some embodiments, the receptable may be made of aluminum with a specific thickness and heat transfer rate demonstrated to easily thaw the outer surface of the puck. In some embodiments, the receptable may be made of any other suitable material such that the combination of the material's heat transferrate and thickness allows heat to be added to the frozen contents faster than it can diffuse through the body of the frozen contents.

[0074] In some embodiments, the frozen liquid content is cooled significantly below its freezing point. Various sources may be used to accomplish this, including but not limited to, dry ice, liquid nitrogen, liquid carbon dioxide, liquid helium, ammonia or other refrigerants freon or freon substitutes, or combination thereof.

[0075] In some embodiments, the receptacle is filled via a liquid filler and sealed before being put through a freezer tunnel with a certain length, flow rate, and duration to exit the receptacle at a specific temperature below the liquid content's freezing point. [0076] In some embodiments, the liquid contents are frozen at the bottom of a receptable with tapered sidewalls. In some embodiments, the receptable is flipped onto a top endcap or lid, such that the frozen liquid content may drop via gravity assistance from its frozen position at the bottom of the receptable to the downward facing top of the receptable once dislodged with heat. In some embodiments, agitation is applied to the receptable to allow the frozen liquid beverage contents to move to a second position or multiple positions within the capsule when partially liquified. Agitation may include shaking, twisting, swirling, twirling, flipping, spinning, combinations thereof or any other movement.

[0077] In some embodiments, an amount of heat is applied to a receptable with a given thermal conductivity rating such that the heat overpowers the outer surface of the puck and liquifies only the outer layer of the frozen liquid beverage content adhered to the interior of the receptacle. The heat source may be any form of heat, including hot air, a heated liquid, steam, microwave energy, IR radiation, radio frequency heating, an applied (contact) heated surface, or any other known form of heat. The duration and temperature may vary to apply a specific amount of heat. In some embodiments, the inner or outer surface of the receptacle is coated with a material that reacts with radio frequency or other heating method to more effectively transfer heat into the outer layer of the liquid frozen contents. This latter approach is especially useful if the packaging material is otherwise of low thermal conductivity, e.g., a paper-based or plastic material.

[0078] In some embodiments, the receptacle is heated while on a conveyor that assists in controlling the amount of heat applied to the receptacle via the conveyor's speed and/or the stopping and starting of the conveyor. In some embodiments, the conveyor works in combination with a heat source to apply enough heat to partially liquefy at least a portion of the surface layer of the frozen liquid contents. In some embodiments, the conveyor agitates or vibrates in a way that prevents the frozen puck from re-adhering to the sidewalls of the receptacle.

[0079] In some embodiments, at least a portion of the surface layer of the frozen liquid content is partially liquified and the contents moves to a second position within the receptable. In some embodiments, heat is stopped once the surface of the puck thaws and the core of the frozen liquid beverage contents subsequently reacts with the partially liquified portion of the liquid beverage contents and is cold enough to refreeze the partially liquified portion in the second, loosened position. In some embodiments, agitation is applied while the core refreezes the liquefied portions to prevent it from adhering to the second position within the receptable.

Claims

1. A method of producing a receptacle containing frozen liquid contents, comprising: providing a receptacle having an interior; introducing a liquid into the interior of the receptacle; freezing the liquid in the interior to produce a frozen liquid contents in the interior, wherein the frozen liquid contents adhere to the receptacle at a first position in the interior; heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents to dislodge the frozen liquid contents from the first position in the interior of the receptacle; and moving the receptacle to reposition the dislodged frozen liquid contents in the receptacle.

2. The method of claim 1, wherein moving the receptacle to reposition the dislodged frozen liquid contents comprises repositioning the dislodged frozen liquid contents to a second position in the interior receptacle and allowing the dislodged frozen liquid contents to refreeze and adhere to the interior of the receptacle at the second position.

3. The method of claim 1, wherein moving the receptacle to reposition the dislodged frozen liquid contents comprises keeping the dislodged frozen liquid contents in motion for a period of time sufficient to allow the dislodged frozen liquid contents to refreeze without adhering to the interior of the receptacle.

4. The method of any one of claims 1-3, wherein moving the receptacle comprises one or more of flipping, rotating, rocking, whirling, rotary or linear reciprocation, shaking and vibrating.

5. The method of any one of claims 1-4, wherein the solid frozen liquid content includes at least one of: a frozen coffee extract; a frozen tea extract; a frozen lemonade concentrate; a frozen vegetable concentrate; a frozen broth; a frozen liquid dairy product; a frozen alcohol -based product; a frozen concentrated soup; a frozen syrup; a frozen fruit concentrate; a vitamin water; and a nutraceutical mixture.

6. The method of any one of claim 1-5, wherein freezing the liquid in the interior to produce a frozen liquid contents comprises freezing the frozen liquid contents to a temperature at least 10 °F below a freezing point of the frozen liquid contents.

7. The method of claim 6, wherein freezing the frozen liquid contents comprises the use of one or more of dry ice, liquid nitrogen, liquid carbon dioxide, liquid helium, ammonia, freon, and freon substitutes.

8. The method of any one of claims 1-7, wherein heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents comprises heating the receptacle.

9. The method of claim 8, wherein heating the receptacle comprises providing a heated fluid proximate to an exterior surface of the receptacle.

10. The method of claim 8, wherein heating the receptacle comprises applying heat to the receptacle from a heat source selected from the group consisting of hot air, a heated liquid, steam, microwave energy, IR radiation, radio frequency heating, an applied (contact) heated surface and combination thereof.

11. The method of any one of claims 1-10, wherein the receptacle comprises a cup-like body and a closure disposed over the body sealing the receptacle and defining the interior of the receptacle.

12. The method of claim 11, wherein the closure comprises a removable lid.

13. The method of claim 11, wherein the cup-like body comprises a hemispherical shaped body.

14. The method of any one of claims 1-10, wherein the receptacle comprises: a sidewall extending from a first end of the receptacle to a second end of the receptacle, at least a portion of the sidewall being tapered; a continuous end layer disposed at the first end of the receptacle, the continuous end layer transitioning from the sidewall at a boundary between the sidewall and the continuous end layer, the boundary encompassing the continuous end layer, the continuous end layer lacking openings within the continuous end layer encompassed by the boundary, and the continuous end layer defining an unbroken inner surface and a corresponding unbroken outer surface; a closure disposed at the second end of the receptacle, the sidewall, the continuous end layer, and the closure defining the interior of the receptacle.

15. The method of any one of claims 1-14, further comprising sealing the receptacle prior to introducing the liquid into the interior of the receptacle, wherein the liquid is introduced to the interior of the receptacle through an inlet in the receptacle.

16. The method of any one of claims 1-14, further comprising sealing the receptacle after introducing the liquid into the interior of the receptacle.

17. The method of any one of claims 1-16, wherein the receptacle comprises aluminum.

18. The method of any one of claims 1-17, wherein at least one of: freezing the liquid in the interior to produce a frozen liquid contents in the interior; heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents to dislodge the frozen liquid contents from the first position in the interior of the receptacle; and moving the receptacle to reposition the dislodged frozen liquid contents; occurs while the receptacle moves along a conveyor.

19. A method of producing a receptacle containing frozen liquid contents, comprising: providing a receptacle having an interior containing frozen liquid contents in the interior, wherein the frozen liquid contents adhere to the receptacle at a first position in the interior; heating the frozen liquid contents to at least partially thaw a portion of a surface layer of the frozen liquid contents to dislodge the frozen liquid contents from the first position in the interior of the receptacle; and moving the receptacle to reposition the dislodged frozen liquid contents in the receptacle.

20. The method of claim 19, wherein moving the receptacle to reposition the dislodged frozen liquid contents comprises repositioning the dislodged frozen liquid contents to a second position in the interior receptacle and allowing the dislodged frozen liquid contents to refreeze and adhere to the interior of the receptacle at the second position.

21. The method of claim 19, wherein moving the receptacle to reposition the dislodged frozen liquid contents comprises keeping the dislodged frozen liquid contents in motion for a period of time sufficient to allow the dislodged frozen liquid contents to refreeze without adhering to the interior of the receptacle.