BEVERAGE CONTAINER WITH INSULATIVE PROPERTIES

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to EP Application Serial No. 24460045.8, filed Dec. 20, 2024, which is hereby incorporated by reference in its entirety for all purposes.

BACKGROUND

Beverage and/or food storage cans, bottles, and other containers are often formed from plastic, aluminum, steel, or glass. These containers may be decorated using inks in order to produce designs and labels of various colors and finishing effects. However, based on the thermal properties of the container, the contents of the container may change temperature rapidly. Aluminum, for example, being a good conductor of heat, is sensitive to temperature changes. When a person holds a beverage can, for example, the heat from their hand may be transferred through the container and may undesirably warm the contents of the container. Thus, improvements are needed to better protect the contents of the container from unwanted heat exchange.

BRIEF SUMMARY

A beverage container may include a container comprising a sidewall having an exterior surface and an interior surface. The container may include an inner thermally insulative coating applied to the inner surface. The inner thermally insulative coating may have a thickness of between 2 microns and 10 microns. The container may include an outer thermally insulative coating applied to at least a portion of the exterior surface. The outer thermally insulative coating may include a plurality of discrete protrusions about the at least a portion of the exterior surface. The plurality of discrete protrusions may be separated by one or more channels.

In some embodiments, at least a subset of the plurality of discrete protrusions may include at least one lateral dimension that is greater than 1 mm. A thickness of the outer thermally insulative coating may be between 6 microns and 140 microns. The outer thermally insulative coating may include a region devoid of the plurality of discrete protrusions. The region may include a thickness of between 3 microns and 15 microns. A total thickness defined by a thickness of the inner insulative coating, a thickness of the sidewall, and a thickness of the outer thermally insulative coating may be between 55 microns and 400 microns. An average height of the plurality of protrusions may be between 6 microns and 140 microns. The at least a portion of the exterior surface may include between 25% to 85% of a total outer surface area of the sidewall. The plurality of protrusions may include predefined shapes arranged in a regular pattern. The plurality of protrusions may include irregular shapes arranged in a random pattern. The outer insulative coating may include an ink and a varnish. The inner insulative coating and the outer insulative coating may reduce a rate of thermal transfer of the beverage container by at least 8% relative to a beverage can of similar structure that does not include the inner insulative coating and the outer insulative coating.

Some embodiments of the present technology may encompass beverage containers that may include a container comprising a sidewall having an exterior surface and an interior surface. The containers may include an inner thermally insulative coating applied to the inner surface. The inner thermally insulative coating may have a thickness of between 2 microns and 10 microns. The containers may include an outer thermally insulative coating applied to at least a portion of the exterior surface. The outer thermally insulative coating may have a maximum thickness of between 3 microns and 140 microns. The outer insulative coating may have a substantially uniform thickness across a surface area of the outer insulative coating. The outer insulative coating may have a variable thickness across a surface area of the outer insulative coating.

Some embodiments of the present technology may encompass methods of manufacturing a beverage container. The methods may include applying an outer insulative coating to at least a portion of an exterior surface of a sidewall of a beverage container. The outer thermally insulative coating may have a maximum thickness of between 3 microns and 140 microns. The methods may include applying an inner insulative coating to an interior surface of the sidewall. The inner thermally insulative coating may have a thickness of between 2 microns and 10 microns. The methods may include applying heat to the beverage container to cure the inner insulative coating and the outer insulative coating.

In some embodiments, applying heat to the beverage can may include applying heat to the beverage container a first time prior to applying the inner insulative coating to cure the outer insulative coating and applying heat to the beverage container a second time after applying the inner insulative coating to cure the inner insulative coating. The outer insulative coating may include a plurality of discrete protrusions that are separated by one or more channels. Applying the outer insulative coating may be done using one or more of a spray coater, a smooth roller, a textured roller, a printer, or a lithography tool. The inner insulative coating may include a BPA-NI lacquer. Applying the inner insulative coating may include spraying the inner insulative coating onto the interior surface of the sidewall.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a schematic view of a portion of a production line 100 for producing beverage cans, such as aluminum cans.

FIGS. 2A-2D illustrate one example of a container 200 with insulative properties, according to certain embodiments.

FIG. 3 is a flowchart illustrating a process for applying an insulative coating to a beverage container.

FIGS. 4A-4C illustrate a graph showing temperature over time of a beverage container, according to certain embodiments.

DETAILED DESCRIPTION

Embodiments of the present invention are directed to systems and methods for manufacturing product containers (e.g., food and/or beverage cans, bottles, and the like) that include images, colors, etc. (collectively, “decorations”) that have thermally insulating properties. Aluminum may frequently be used to manufacture storage containers (e.g., cans) for food, beverages, and/or other objects in a wide variety of applications. Aluminum, however, is a relatively good conductor of heat, meaning that the temperature of the content of the container may gain or lose heat rapidly. For example, when a beverage container is removed from a refrigerator and held in a person's hand, the heat from the person's hand may be transferred through the beverage container and warm the contents.

Embodiments of the present invention are directed to systems and methods for manufacturing product containers (e.g., food and/or beverage cans, bottles, and the like) that improve the insulative properties of the containers to slow thermal transfer between the container and the external environment to better maintain the contents of the container at a desired temperature. Embodiments of the present invention may reduce the rate of heat transfer from a user's hand to the contents of the container (e.g., increase the time the contents are at a desired temperature) by 8% or more. For example, the containers described herein may include insulative coatings that may cover all or a portion of interior and exterior surfaces of the containers. In some embodiments, an insulative coating on an exterior surface of the container may include a continuous layer of insulative material and/or may include a number of discontinuous, discrete regions of insulative material. For example, in some embodiments the external surface may include a number of discrete regions of the insulative material that form protrusions that extend away from the outer surface of the container. The insulative coatings may be applied with larger footprints (e.g., a larger percentage of the surface area of the container) and/or at greater thicknesses than traditional finishing materials used on conventional containers.

In some embodiments having protrusions formed from the insulative coating, some or all of the protrusions may have at least one lateral dimension that is greater than 1 mm and may have maximum heights of between 20 microns and 80 microns. The protrusions may include regular and/or randomly-generated shapes and/or may be arranged in regular or irregular patterns about the exterior surface of the container. In some embodiments, some of the protrusions may include dimples or other features (which may or may not have relatively pointed edges) formed along an upper surface of the protrusions. The presence of the protrusions (and subsequent channels formed between adjacent protrusions) and/or air bubbles may help reduce the contact area between a user's hand and the container body, thus reducing the rate of thermal transfer from the user's hand to the contents of the container. The presence and thickness of the insulative coating, as well as the presence of protrusions when included, may improve the insulation of the container and help maintain the contents of the container at a desired temperature for a longer duration. In some embodiments, the insulative coating applied to the exterior surface of the container have a thickness within a range of 2 microns to 80 microns.

The containers may additionally or alternatively include an insulative coating that is applied to an interior surface of the container to further improve the insulative properties of the container. By applying an internal lacquer or other insulative coating to a thickness within a range of 2 microns to about 10 microns, the container may have even greater insulative properties.

While described primarily in the context of beverage cans, it will be appreciated that the systems and methods described herein may be utilized in other container manufacturing processes, especially those in which temperature sensitivity of the container contents is a concern. Additionally, the techniques described herein are not limited to aluminum beverage cans and may be utilized in other applications (such as other canning operations, bottling operations, and/or other operations in which a specific package is filled with a particular object and/or substance) and/or with other materials, such as other metals, glass, and/or plastic materials.

FIG. 1 illustrates a schematic view of a portion of a production line 100 for producing beverage cans, such as aluminum cans. Production line 100 will be described as including a number of different devices and is merely representative of one example of a production line. It will be appreciated that numerous variations may exist, and that functionality described in relation to one or more devices may be combined and performed by a single device in some embodiments, while in other embodiments functionality attributed to a single device may be performed by a number of distinct devices. Additionally, some embodiments may include additional steps and/or omit one or more steps. Production line 100 may include a number of components that form can bodies from can blanks and/or metallic sheets, such as via a number of presses, dies, punches, doming tools, and trimmers. Once the can bodies are formed, number of washing and/or etching operations may be performed on each can body to wash away lubricants and/or other materials and/or to prepare the surface of the can body for printing. After washing, the can blanks may be transported to a dryer that may dry the can blanks prior to applying any decoration to the can blank.

The dried can blanks may be transported to a decorator 102, which may apply a decoration (such as a brand name, product name, nutrition information, etc.) to an outer surface of the can blank. In some embodiments, the decoration may be formed from and/or otherwise include one or more materials that form a thermally-insulative coating on all or a portion of the exterior of the can. The decorator 102 may apply any decoration to the outer surface of the can blank in one or more steps. For example, the decorator 102 may be an 8-color offset machine (or other number of colors) that may apply ink to the outer surface of the can blank using a rotation printing process to generate a desired decoration. It will be appreciated that any number of types of decorators 102 may be used in various embodiments. For example, the decorator 102 may include a lithography tool, a printer (e.g., an inkjet printer), a spray applicator, a roll coating apparatus, and/or other tool that may be used to apply one or more inks and/or varnishes to an exterior surface of the can. After printing the decoration, the decorator 102 may apply an overprint varnish to the ink. A bottom of the can may be rim-coated, which may help facilitate rotation and/or other movement of the can blank along the production line. The decorated can blanks may be cured and/or partially cured within a pin oven 104 to harden the ink and varnish.

The cured can blanks may be transported to a lacquer applicator 106. The lacquer applicator may include a sprayer or other application device to apply material to the inside of a can blank. The lacquer applicator 106 may apply an inner coating such as a thermally-insulative coating on an interior surface of the can. For example, in some embodiments, the insulative coating may be or otherwise include a food-grade lacquer that is applied to an interior surface of each can. The internal lacquer may help ensure that the final beverage and metal do not contact and/or react with one another, while also providing a level of thermal insulation that helps slow thermal transfer from a user's hand and the external environment to the beverage. For example, the internal lacquer may prevent a beverage from eating through the metal and may also prevent materials from the metal from leeching into and/or reacting with the beverage.

The internal lacquer may include a food-safe resin (e.g., polycarbonate including bisphenol A (BPA) or BPA-NI) or any other suitable coating. In some embodiments, the internal coating substantially free of formaldehyde, bisphenols, isocyanates, phthalates, styrene, and/or organotins. As used herein. the term “substantially free” means that there is no more than 1.0% by weight, preferably no more than 0.5% by weight, and more preferably no more than 0.1% by weight of the compound, or structural units derived from the compound, present in the coating composition. For example, in some embodiments, the internal lacquer may be or include a water and/or other organic solvent-based lacquer. In some embodiments, the internal lacquer may include latex, such as a coating that includes latex and a hydroxyphenyl functional polymer. The insulative coating may be applied in a single spraying operation of the lacquer applicator 106, or multiple layers of material may be sprayed to generate the inner coating. In one embodiment, the inner coating may be applied to the inside surface of the can blank such that an average thickness of the internal coating is between 2 microns and 10 microns, between 2.5 microns and 7 microns, or between 3.5 microns and 6 microns. The internal lacquer may be dried within a curing oven 108, which may be a pin oven in some embodiments.

Once the insulative coatings have been applied to the cans, the cans may be transported to downstream components of the production line 100 that fill and seal the cans for shipment. In some embodiments, prior to and/or during filling, the liquid may be pasteurized to kill bacteria within the can. After the cans have been heated to the necessary temperature to sufficiently pasteurize the contents, the cans may be cooled prior to palletization, such as by spraying the cans with cool water to help prevent the formation of condensation on the outside of the cans, which may damage cardboard used in the palletization/packing process.

Transportation of the cans/blanks between the various devices may be performed by different conveyor mechanisms throughout the manufacturing process. The mechanism chosen for a given stage may depend on a number of lines of cans entering and/or exiting a given device, a desired throughput, a desired orientation of the cans entering and/or exiting a given device, a current state of the cans entering and/or exiting a given device, and/or other factors. Possible conveyor mechanisms may include conveyor belts, vacuum conveyors (such as vacuum bridges), chain conveyors, roller conveyors, chute conveyors, vertical conveyors, wheel conveyors, pneumatic conveyors, and/or other conveyor mechanisms.

FIGS. 2A-2C illustrate one example of an insulative container 200, according to certain embodiments. As illustrated, container 200 may be an aluminum can. In other embodiments, container 200 may be a glass bottle, plastic bottle, and/or other form of beverage container. Container 200 may include a container body 202 having a base 204, a generally cylindrical sidewall 206, and a neck 208. In some embodiments, a top may be affixed to a top end of neck 208 and may include a tab for opening the top. Container 200 may take other forms in various embodiments. In some embodiments, sidewall 206 may have a thickness of between 50 microns and 250 microns, between 60 microns and 240 microns, between 70 microns and 230 microns, between 80 microns and 220 microns, between 100 microns and 200 microns, between 120 microns and 180 microns, or between 140 microns and 160 microns, although other thicknesses are possible in various embodiments. Some or all of the exterior surface (e.g., of the sidewall 206) of container 200 may include an outer insulative coating 210 while some or none of the exterior surface of container 200 may be devoid of outer insulative coating 210.

Outer insulative coating 210 may be formed on between 30% and 100% of the exterior surface of the sidewall 206 in various embodiments. Outer insulative coating 210 may be formed from various materials that provide one or more continuous and/or discontinuous regions of thermally-insulative material that extend from the exterior surface of the sidewall 206 and that help slow the rate of thermal transfer from the external environment and/or a user's hand to the contents of container 200. An average thickness of outer insulative coating 210 may be between 3 microns and 100 microns in various embodiments. The thickness of outer insulative coating 210 may be substantially uniform (e.g., with variations of less than 10% from the average thickness, less than 5%, less than 3%, less than 1%, or less) across a surface area of outer insulative coating 210 in some embodiments, while in other embodiments the thickness of outer insulative coating 210 may vary across the surface area of outer insulative coating 210.

In a particular embodiment in which the thickness of outer insulative coating 210 varies across the surface area of outer insulative coating 210, outer insulative coating 210 may be applied to the exterior surface of sidewall 206 in manner such that a number of discrete regions of varying thickness are provided. For example, the discrete regions may include a number of thick protrusions that are each separated by channels of a lower thickness that extend between adjacent protrusions. The protrusions may include regular and or predefined shapes, such as polygons (e.g., triangles, rectangles, pentagons, hexagons, etc.), circles, ovals, ellipses, and/or other known shapes. In some embodiments, the protrusions may include randomly-generated and/or otherwise irregular shapes, such as shapes that occur as a result of reactions between different materials and/or using coating application processes that do not produce predefined shapes. The protrusions may be arranged in regular or irregular patterns about the exterior surface of the container. The protrusions may be arranged over all or substantially all of the surface area of outer insulative coating 210 or may be arranged over only a portion of the surface area of outer insulative coating 210. For example, in some embodiments, the protrusions may be provided only within a region of the exterior surface of sidewall 206 that is most likely to be grasped by a user. As just one example, the protrusions may be arranged within a central 50%-80% of a length of sidewall 206 and/or extend about between 25%-100% of a circumference of sidewall 206. For example, as illustrated in FIG. 2A, the protrusions may be provided only within region 210a of outer insulative coating 210, while region 210b of outer insulative coating 210 is devoid of protrusions and may have a substantially uniform thickness of outer insulative coating 210. As illustrated, region 210a covers a roughly centered portion of sidewall 206. The location of region 210a on container 200 may be determined as the most likely location for a person to hold container 200 while in use. Thus, container 200 may be most thermally insulated where the contact and heat exchange between the person's hand and container 200 is likely to be the greatest. However, in other embodiments, the protrusions may extend about more or less of the length and/or circumference of sidewall 206 and/or at different locations.

Regions 210a may individually and/or collectively cover any percentage of the outer surface of sidewall 206 (and possibly some or all of neck 208 and/or base 204). For example, regions 210a may individually and/or collectively cover between 5% and 90%, of the outer surface of sidewall 206, between 25% and 90%, more preferably from 30% and 75%, and most preferably between 35% to 65% of the outer surface of sidewall 206. Regions 210b may individually and/or collectively cover from 15% to 75%, more preferably from 25% to 70%, and most preferably from 35% to 65% of the total outer surface area of container 200.

While shown with a single region 210a and two regions 210b, it will be appreciated that outer insulative coating 210 may include any number of regions 210a and/or 210b. For example, outer insulative coating 210 may include one or more regions 210a, two or more regions 210a, three or more regions 210a, four or more regions 210a, five or more regions 210a, ten or more regions 210a, twenty or more regions 210a, 50 or more regions 210a, or greater. Similarly, outer insulative coating 210 may include one or more regions 210b, two or more regions 210b, three or more regions 210b, four or more regions 210b, five or more regions 210b, ten or more regions 210b, twenty or more regions 210b, 50 or more regions 210b, or greater. In some embodiments, outer insulative coating 210 may include only one or more regions 210a or one or more regions 210b.

The protrusions of outer insulative coating 210 may have any size or shape. For example, in some embodiments, each protrusion (or substantially all protrusions, (e.g., at least 75% of protrusions, at least 80% of protrusions, at least 85% of protrusions, at least 90% of protrusions, at least 95% of protrusions, or more)) may have a largest lateral dimension that is at least 0.5 mm, at least 1 mm, at least 1.1 mm, at least 1.2 mm, at least 1.25 mm, at least 1.5 mm, at least 1.75 mm, at least 2 mm, at least 2.25 mm, at least 2.5 mm, at least 3 mm, or larger, such as up to 5 mm, with at least some of the protrusions having a largest lateral dimension of between 1 mm and 5 mm. In some embodiments, at least 25%, at least 50%, or at least 75% of the protrusions may have a largest lateral dimension of between 1 mm and 5 mm. Some or all of the protrusions (e.g., at least 75% of protrusions, at least 80% of protrusions, at least 85% of protrusions, at least 90% of protrusions, at least 95% of protrusions, or more) may have average heights (e.g., thicknesses from the exterior surface of sidewall 206 to a greatest thickness of the protrusion) of between 10 microns and 150 microns. For example, some or all protrusions may have maximum heights of at least 20 microns, at least 30 microns, at least 40 microns, at least 45 microns, at least 50 microns, at least 55 microns, at least 60 microns, at least 70 microns, at least 80 microns, at least 100 microns, at least 125 microns, at least 150 microns, or greater, with at least some of the protrusions having heights of at least 40 in some embodiments. Each protrusion may include a constant height or variable height across the surface area of the protrusion. The height of the protrusion may be determined based on a method of forming the protrusion as described in greater detail below. The channels between the protrusions may have thicknesses (as measured from the exterior surface of sidewall 206) of between 0 microns and 40 microns in various embodiments. For example, in some embodiments the channels are formed in areas that are completely devoid of insulative coating, while in other embodiments the channels are formed in areas where insulative coating is thinner than at the protrusions. The presence of the protrusions and channels may help further thermally insulate container 200 from a user's hand by reducing the contact area between the user's hand and sidewall 206, as the channels create air gaps between the user's hand and sidewall 206.

The protrusions may be formed through various processes of applying outer insulative coating 210. For example, the protrusions may be formed by using a textured roller to apply insulative coating, using a spray applicator to apply one or more uneven (e.g., nonuniform) layers of outer insulative coating 210, using an inkjet printer (or other form of printer) to apply a textured pattern of outer insulative coating 210, relying on a reaction between different materials of insulative coating to produce the protrusions, and/or may include other techniques.

Region 210b may include outer conductive coating at a thickness of between 3 microns to 15 microns, more preferably between 3 microns and 10 microns, and most preferably between 3 microns and 6 microns.

In some embodiments, outer insulative coating 210 may include, without limitation, inks and/or varnishes that may be used to form part of a decoration of container 200. For example, outer insulative coating 210 may include an ink and/or varnish that is used to generate and/or protect the decoration of container 200, which may include branding and nutritional information in various embodiments. Other components, such as insulative polymers, waxes, and the like, may be incorporated into outer insulative coating 210 in various embodiments.

As noted above, outer insulative coating 210 may include a number of protrusions of predefined shapes that are arranged in repeating, randomized, or other predefined patterns of predefined and/or random/irregular shapes about the outer surface. The predefined shapes may include circles, rectangles, logos, images, numbers, letters, other polygons, and/or other shapes that are defined using a lithographic mask, textured roller, printer, and/or other technique. For example, a pattern of predefined shapes and predefined voids (e.g., channels) between the shapes may be applied using one or more inks, varnishes, and/or other materials (e.g., insulative polymers). Some or all of the materials of outer insulative coating 210 may be applied with varying thicknesses in predefined and/or random patterns to generate the protrusions and channels. In one particular embodiment, predefined shapes may be applied using varnish-antagonistic ink and the voids may be applied using varnish-compatible ink, such as by using a lithography mask and/or printer to apply the different inks in a predefined pattern. Varnish may be applied atop the different inks, with the varnish flowing away from the varnish-antagonistic ink present in the predefined shapes and collecting within the voids to form protrusions having predefined shapes matching shapes of the voids in the lithographic mask. Such a textured pattern of protrusions 222a and voids or channels 224a is illustrated in FIG. 2C. In some such embodiments, the pattern of shapes and voids may be regular such that repeating pattern of protrusions 222a is created, with consistent spacing between protrusions 222a.

In other embodiments, such as shown in FIG. 2D, protrusions 222b may be randomly oriented with random/irregular shapes about the exterior surface of a container. The random/irregular shapes may be formed as a result of the manufacturing process of protrusions 222b and may have any number of curves (e.g., concave and/or convex regions) and variable lateral dimensions taken across different angular positions of a given protrusion 222b. For example, in some embodiments, a region of outer insulative coating 210 may be coated in one or more varnish-antagonistic inks and a varnish may be applied across all or a portion of the region. The presence of the varnish-antagonistic inks may cause the varnish to accumulate in random, discrete regions of different sizes and/or shapes, which may lead to the formation of protrusions 222b separated by channels 224b. In such embodiments, distances and directions between adjacent protrusions 222b may be entirely random such that no two containers 200 have a same layout of protrusions 222b. In some instances, no two protrusions 222b on container 200 may have a same shape or size. At least 50%, at least 75%, at least 90%, or greater of all protrusions 222b on a given container 200 may be unique in some embodiments.

In some embodiments, an upper surface of at least some of protrusions 222 may include at least one popped air bubble 226 as shown in FIG. 2D. Popped air bubbles 226 may be formed, for example, by carefully controlling a drying time and/or temperature during formation of protrusions 222. For example, during formation, air bubbles may form that subsequently burst to form popped air bubbles 226, which may take the form of dimples or other features within upper surfaces of some or all protrusions 222. The presence of such dimples may further reduce the contact area between a person's hand and sidewall 206 to reduce the rate of thermal transfer from the person's hand to the contents of container 200.

The inks included within outer insulative coating 210 may include one or more varnish-compatible inks (e.g., inks on which a varnish may be readily adhered and that do not affect the overlaying varnish) and/or one or more varnish-antagonistic inks (e.g., inks that do not readily receive varnish and that may cause an overlaying varnish to agglomerate to some degree). The varnish-compatible inks used herein may have surface tensions (when dry) that exceed 35 mN/m², which may enable varnishes to adhere to the ink without being affected. In contrast, the varnish-antagonistic inks used herein may have surface tensions (when dry) that are less than 30 mN/m², less than 25 mN/m², less than 20 mN/m², or less. Suitable varnish-antagonistic inks may include, without limitation, INX No Varnish inks, INX NOVAR inks, Sun Chemical SUNDUO inks, and/or Sun Chemical COMET inks. The inks used herein may be clear and/or may include pigments of any color.

The varnishes used to produce the protrusions may have higher surface tensions than the inks, and in particular than the varnish-antagonistic inks. For example, the varnishes may have surface tensions (when wet) that are higher than the inks, with larger differences in surface tension between the varnish and the varnish antagonistic inks leading to greater protrusion sizes. The varnishes may have high solids content of between about 34% and 80% solids, and more commonly between 50% and 70% solids. Varnishes having even higher solids contents (e.g., up to 100% solids) may be used in some embodiments. For example, varnishes with solids contents over 80% may be used in conjunction with larger volumes of varnish and/or slower ink and/or varnish application speeds may be used to create larger protrusions, such as protrusions having lateral dimensions that are between about 2.5 mm and 5 mm. Varnishes may also include between about 0% and 30% by weight of one or more solvents and/or between about 0{circumflex over ( )} and 60% by weight of water. In some embodiments, the varnishes may include water-based polyester varnishes. The varnishes may have densities of between 1.015 and 1.115 kg/L. In some embodiments, the varnishes may include, without limitation, a lactam and one or more resins (which may be hydrophobic), such as an alkyd resin, an acrylic resin, a polyester resin, a polyester polyol resin. a silicone-based resin, a phenolic resin. a urethane-based or isocyanate=based resin, an aminoplast, and/or an epoxy resin. Suitable varnishes may include, without limitation, Metlac 815675, BPANI/PFASNI 815788, PPG 9319-801, PPG9442-801A, Novochem Novoshield 4975B, and/or Novochem Novoshield 4765. In some embodiments, additional insulating materials, such as thermally insulating polymers, may be added to the ink and/or varnish to further enhance the insulative properties of outer insulative coating 210.

It will be appreciated that the techniques described above for generating random and/or predefined shapes and sizes of protrusions in random or predefined patterns are merely examples and that numerous techniques may be used to vary the thickness of outer insulative coating 210 and/or to create the protrusions and voids/channels of a textured insulative coating.

FIG. 2B illustrates a cross-sectional top plan view of container 200, according to certain embodiments. As illustrated, container 200 includes sidewall 206 (with a thickness of between 50 microns and 250 microns). Outer insulative coating 210 is applied to at least a portion of the exterior surface of sidewall 206. As noted above, a thickness of outer insulative coating 210 may be between 3 microns and 140 microns, between 5 microns and 130 microns, between 10 microns and 120 microns, between 15 microns and 110 microns, between 20 microns and 100 microns, between 30 microns and 90 microns, or between 40 microns and 80 microns. For example, where outer insulative coating 210 is applied at a substantially uniform thickness, a thickness of outer insulative coating 210 may be between 3 microns and 15 microns, between 4 microns and 14 microns, between 5 microns and 13 microns, between 6 microns and 12 microns, between 7 microns and 11 microns, or between 8 microns and 10 microns. Where outer insulative coating 210 is applied with a variable thickness (e.g., as a number of protrusions and channels), a maximum thickness of outer insulative coating 210 (e.g., outermost radial point of a protrusion) may be between 6 microns and 140 microns and more commonly between 7 microns and 139 microns at each of the protrusions, between 8 microns and 138 microns, between 9 microns and 137 microns, between 10 microns and 135 microns, between 15 microns and 130 microns, between 20 microns and 125 microns, between 30 microns and 120 microns, between 40 microns and 115 microns, between 50 microns and 110 microns, between 60 microns and 100 microns, or between 70 microns and 90 microns.

An inner insulative coating 216 may be applied (e.g., sprayed) on an interior surface of the container 200. Inner insulative coating 216 may include a food-safe resin (e.g., polycarbonate including bisphenol A (BPA) or BPA-NI), or any other suitable insulative coating. Inner insulative coating 216 may be applied in a single spraying operation, or multiple layers of material may be sprayed to generate inner insulative coating 216. In one embodiment, inner insulative coating 216 is applied to the interior surface of the container 200 such that an average thickness of internal insulative coating 216 is in the range of from 2 microns to 10 microns. For example, a thickness of inner insulative coating may be between 2.5 microns and 9 microns, between 3 microns and 8 microns, between 3.5 microns and 7 microns, or between 4 microns and 6 microns. The thickness of inner insulative coating 216 may be adjusted by altering a spray time of a device in the production line 100, such as lacquer applicator 106.

In some embodiments, a total thickness of inner insulative coating 216, sidewall 206, and outer insulative coating may be between 55 microns and 400 microns. For example, inner insulative coating 216 may have a thickness of between 2 microns and 10 microns, sidewall 206 may have a thickness of between 50 microns and 250 microns, and outer insulative coating 210 may have a thickness of between 3 microns and 140 microns. The collective thicknesses of each layer may provide enhanced insulative properties over conventional containers, while the combination of protrusions and channels (when present) help reduce a contact area between a user's hand and container 200 to further reduce a rate of thermal transfer to the contents of container 200. Such insulative properties may be further improved by selecting materials (e.g., polymers, inks, varnishes, etc.) for inner insulative coating 216 and/or outer insulative coating 210 that have strong thermal insulating properties. Thicker insulative coatings 210, 216 may improve the insulative properties of container 200. Collectively, inner insulative coating 216 and outer insulative coating 210 may provide a reduction in thermal transfer from a user's hand to the contents of container 200 by at least 7.5%, at least 8%, at least 10%, at least 12%, at least 15%, at least 20%, or more compared to a container of similar structure that does not include inner insulative coating 216 and/or outer insulative coating 210.

FIG. 3 is a flowchart illustrating a process 300 for applying insulative coatings to a beverage container. Process 300 may be performed using a production line, such as production line 100 described herein and may be used to create containers, such as container 200. Process 300 may begin at operation 305 by applying an outer insulative coating (e.g., outer insulative coating 210) to at least a portion of an exterior surface of a sidewall of a beverage container, such as container 200. The outer insulative coating may be applied using a printing device, a lithography tool, a spray coater, a roller (e.g., a smooth roller and/or a textured roller), and/or other coating device. The portion of the exterior surface on which the outer insulative coating is applied may include all or a portion of a sidewall of the container. Typically, the portion of the outer surface on which the outer insulative coating is applied is limited to the sidewall, with the base and/or neck of the container being devoid of the outer insulative coating, however in some embodiments the outer insulative coating may be applied to other regions of the container.

The outer insulative coating may have a substantially uniform thickness across all or a portion of a surface area of the outer insulative coating and/or may have a variable thickness across all or a portion of a surface area of the outer insulative coating. For example, the outer insulative coating may include a plurality of discrete protrusions that are separated by one or channels or voids that cover at least a portion of the surface area of the outer insulative coating. In regions where no protrusions are present, a thickness of the outer insulative coating may be between 3 microns and 15 microns. In regions where protrusions are present, a maximum height or thickness of the protrusions may be between 6 microns and 140 microns, with thicknesses of between 20 microns and 140 microns being more common.

In some embodiments, the outer insulative coating may include one or more inks and/or varnishes that are used to form a decoration of the container. For example, the inks may include clear and/or pigmented inks and, in some embodiments may be applied to create an aesthetic design on the outer surface of the container. The inks may include varnish-compatible inks and/or varnish-antagonistic inks in various embodiments. The varnish-antagonistic inks may be applied uniformly (e.g., as a layer having a substantially consistent thickness) across a portion of the outer surface. In other embodiments, applying the ink may include applying one or more varnish-antagonistic inks and one or more varnish-compatible inks to the portion of the outer surface using lithography techniques. For example, a lithography mask may be used to apply different inks in a repeating pattern of shapes and voids. The predefined shapes may be applied using varnish-antagonistic ink and the voids may be applied using varnish-compatible ink. A varnish may be applied over the ink. In other words, the varnish and the ink may both still be in a wet state when the varnish is applied. In some embodiments, the varnish may be applied in a uniform manner across the ink. The varnish may be applied at a rate of between 6 grams and 15 grams per square meter, with higher rates (possibly with varnishes having higher solids content) being used to generate larger/taller protrusions. Such application rates in protrusions with maximum heights of at least 20 microns, at least 30 microns, at least 40 microns, at least 45 microns, at least 40 microns, at least 55 microns, at least 60 microns, at least 70 microns, at least 80 microns, at least 100 microns, at least 125 microns, at least 140 microns, or greater.

At operation 310, an inner insulative coating (such as inner insulative coating 216) may be applied to an interior surface of the sidewall. For example, the inner insulative coating may be applied by spraying the inner insulative coating onto the interior surface of the sidewall. The inner thermally insulative coating may have a thickness of between 2 microns and 10 microns. In some embodiments, the inner insulative coating may be and/or may include a food grade polymer, such as (but not limited to) a BPA-NI lacquer.

At operation 315, heat may be applied to the beverage container to cure the inner insulative coating and the outer insulative coating. This may be performed in one or more steps. For example, heat may be applied to the beverage container a first time prior to applying the inner insulative coating to cure the outer insulative coating. The heat may be applied via a heating device, such as a pin oven. Once the outer insulative coating has been cured, the inner insulative coating may be applied to an interior of the container. Heat may be applied to the container a second time to cure the inner insulative coating. The heat may be applied via a heating device, such as a curing oven. Other orders of application of the insulative coatings and/or applications of heat may be used in various embodiments. The application of heat may involve exposing the container to a temperature of between 175° C. and 230° C. for between 10 seconds and 60 seconds, although exposure times exceeding 60 seconds (such as up to 120 seconds 180 seconds, or more) may be used in some embodiments, especially where the heating device has a large capacity and/or slow manufacturing speeds are utilized. In embodiments in which varnish-antagonistic ink is utilized to generate protrusions, the heat may initiate a reaction between the ink and the varnish that causes accumulation of the varnish to form the protrusions and channels on the outer surface. The reaction may be caused by the use of low surface tension inks and the difference in surface tension between the ink and the varnish. In some embodiments, the difference in surface tension between the ink and the varnish may be at least 10 mN/m², at least 15 mN/m², at least 20 mN/m², at least 25 mN/m², at least 30 mN/m², or greater.

In some embodiments, the heat may be applied in excess of the curing temperature of the ink, varnish, and/or other components of the outer insulative coating (which may be between 188° C. and 230° C.) for a period of at least one minute. Oftentimes, the heat may be applied at a temperature of at least 188° C. for a period of between 2 minutes and 8 minutes and more commonly between 4 minutes and 6 minutes. Heat may be applied to the beverage container a second time after applying the inner insulative coating to cure the inner insulative coating.

EXAMPLES

In example 1A, a standard aluminum can with a volume of 250 ml was coated with an external coating of Gloss AkzoAquaprime 105 (a standard gloss varnish/lacquer). An internal coating of lacquer (class III aggressiveness) at a thickness of 2.5 microns was applied to an interior of the can. The standard aluminum can was filled with liquid water. The standard aluminum can was then placed in a refrigerator for approximately 24 hours. The standard aluminum can was then removed at a temperature of 7.0° C. A digital thermometer was then inserted into the standard aluminum can and submerged within the liquid water inside the standard aluminum can. Ambient air temperature was approximately 21° C. The can was then held by a person in one hand and then the other, alternating hands every 2 minutes. The temperature of the water was recorded every 15 seconds until the water reached a temperature of 12° C.

In example 1B, an aluminum can with a volume of 250 ml with an insulative coating according to the present disclosure was tested identically to the standard aluminum can in example 1A. In example 1B, the insulative coating was Super Matt-Tactile Novochem Novoshield 49758 at a thickness of 6 microns and having a number of rectangular protrusions arranged in a repeating pattern. The comparison of examples 1A and 1B are summarized in Table 1, below.

FIG. 4A illustrates a graph 400a showing temperature over time of examples 1A and 1B according to the data in Table 1. As seen in the graph 400a, the first line 402a represents the temperature of the standard aluminum can in example 1A (i.e., without the insulative coating). The second line 404a represents the temperature of the aluminum can with the insulative coating in example 1B. Both of the cans 7.0° C. at t=0. The temperature of the water rose as time increased, but at varying rates. The standard aluminum can represented by the first line 402a reaches 12° C. at t=10 minutes. The aluminum can with the insulative coating represented by the second line 404a reaches 12° C. at t=10.5 minutes. Thus, the insulative coating here increased the time for the water to reach 12° C. by 5%.

In example 2A, a standard aluminum can with a volume of 500 ml was coated with an external coating of Gloss Akso Aquaprime 105. No internal coating was applied. A coating of Aqualure 900 at a rate of 3.8 g/m² was applied to the interior of the can. The standard aluminum can was then filled with liquid water. The standard aluminum can was then placed in a refrigerator for approximately 24 hours. The standard aluminum can was then removed at a temperature of 6.7° C. A digital thermometer was then inserted into the standard aluminum can and submerged within the liquid water inside the standard aluminum can. Ambient air temperature was approximately 21° C. The can was then held by a person in one hand and then the other, alternating hands every 2 minutes. The temperature of the water was recorded every 15 seconds until the water reached a temperature of 12° C.

In example 2B, an aluminum can with a volume of 500 ml and an insulative coating according to the present disclosure was tested identically to the standard aluminum can in example 2A. In example 2B, the insulative coating included Super Tactile PPG. An internal coating of lacquer (class III aggressiveness) was also applied to the aluminum can. The comparison of examples 2A and 2B are summarized in Table 2, below.

FIG. 4B illustrates a graph 400b showing a comparison of examples 2A and 2B utilizing the data from Table 2. As seen in the graph 400b, the first line 402b represents the temperature of the standard aluminum can in example 2A. The second line 404b represents the temperature of the aluminum can with an insulative coating in example 2B. Both of the beverage cans were approximately 6.7° C. at t=0. The temperature rose as time increased, but at varying rates. The standard aluminum can represented by the first line 402b reaches 12° C. at t=17 minutes. The aluminum can with the insulative coating represented by the second line 404b reaches 12° C. at t=18.25 minutes. Thus, the insulative coating here increased the time for the water to reach 12° C. by 7.35%.

As seen in the graphs 400a-b, the insulative coatings described herein may increase the time taken for the contents of a beverage can within a range of 8% to 12%. However, one of ordinary skill in the art would recognize that other ranges are also possible. For example, by increasing the size of the protrusions 212 in FIGS. 2C and 2D, the insulative coating(s) may further insulate the contents of the beverage can. Additionally, or alternatively, adding more material to the layers (e.g., increasing a thickness of the inner insulative coating 216 and/or the outer insulative coating 210, etc.) may further reduce the thermal transfer and increase the time taken to warm the contents of the beverage container. Additionally, or alternatively, polymeric and/or other thermally insulating materials may be added to one or more of the coatings in order to further raise the insulative properties of the beverage can. Thus, in some embodiments, the time taken for the contents of the beverage can to warm may be increased by at least 12%, by at least 15%, and/or by at least 20%.

In example 3A, a standard aluminum can with a volume of 500 ml was coated with Gloss Akzo Aquaprime 105. An internal coating of epoxy (class II aggressiveness) was also applied. The standard aluminum can was then filled with liquid water. The standard aluminum can was then placed in a refrigerator for approximately 24 hours. The standard aluminum can was then removed at a temperature of 8.6° C. A digital thermometer was then inserted into the standard aluminum can and submerged within the liquid water inside the standard aluminum can. Ambient air temperature was approximately 21° C. The can was then held by a person in one hand and then the other, alternating hands every 2 minutes. The temperature of the water was recorded every 15 seconds until the water reached a temperature of 12° C.

In example 3B, an aluminum can with a volume of 500 ml and an insulative coating according to the present disclosure was tested identically to the standard aluminum can in example 3A. In example 3B, the insulative coating included Super Tactile PPG. An internal coating of lacquer (class III aggressiveness) was also applied to the aluminum can. FIG. 4C illustrates a graph 400b showing a comparison of examples 3A and 3B. As seen in the graph 400c, the first line 402c represents the temperature of the standard aluminum can in example 3A. The second line 404c represents the temperature of the aluminum can with an insulative coating in example 3B. Both of the beverage cans were approximately 8.6° C. at t=0. The temperature rose as time increased, but at varying rates. The standard aluminum can represented by the first line 402c reaches 12° C. at t=9.75 minutes. The aluminum can with the insulative coating represented by the second line 404c reaches 12° C. at t=11.25 minutes. Thus, the insulative coating here increased the time for the water to reach 12° C. by about 15%.

Specific details are given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, well-known structures and techniques have been shown without unnecessary detail in order to avoid obscuring the embodiments. This description provides example embodiments only, and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the preceding description of the embodiments will provide those skilled in the art with an enabling description for implementing embodiments of the invention. Various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention.

Also, the words “comprise”, “comprising”, “contains”, “containing”, “include”, “including”, and “includes”, when used in this specification and in the following claims, are intended to specify the presence of stated features, integers, components, or steps, but they do not preclude the presence or addition of one or more other features, integers, components, steps, acts, or groups.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly or conventionally understood. As used herein, the articles “a” and “an” refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. By way of example, “an element” means one element or more than one element. “About” and/or “approximately” as used herein when referring to a measurable value such as an amount, a temporal duration, and the like, encompasses variations of ±20% or ±10%, ±5%, or +0.1% from the specified value, as such variations are appropriate to in the context of the systems, devices, circuits, methods, and other implementations described herein. “Substantially” as used herein when referring to a measurable value such as an amount, a temporal duration, a physical attribute (such as frequency), and the like, also encompasses variations of ±20% or ±10%, ±5%, or +0.1% from the specified value, as such variations are appropriate to in the context of the systems, devices, circuits, methods, and other implementations described herein.

Where a range of values is provided, it is understood that each intervening value, to the smallest fraction of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Any narrower range between any stated values or unstated intervening values in a stated range and any other stated or intervening value in that stated range is encompassed. The upper and lower limits of those smaller ranges may independently be included or excluded in the range, and each range where either, neither, or both limits are included in the smaller ranges is also encompassed within the technology, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included.

As used herein, including in the claims, “and” as used in a list of items prefaced by “at least one of” or “one or more of” indicates that any combination of the listed items may be used. For example, a list of “at least one of A, B, and C” includes any of the combinations A or B or C or AB or AC or BC and/or ABC (i.e., A and B and C). Furthermore, to the extent more than one occurrence or use of the items A, B, or C is possible, multiple uses of A, B, and/or C may form part of the contemplated combinations. For example, a list of “at least one of A, B, and C” may also include AA, AAB, AAA, BB, etc.