Abstract:
A wine barrel having a rigid reusable frame with replaceable wooden side panels and substantially identical upper and lower wooden ends assembled within rigid connecting bars to provide a wooden enclosure for the wine. A liquid tight container is provided; the wine exposed only to wooden surfaces or materials non-reactive to wine. Panels can be replaced in the frame with new panels or existing panels having an unused side can be removed, reversed, and reused. Assembly of the barrel is straightforward requiring only minimum tools and skills without the need for the hand-fitting expertise required in constructing a traditional barrel. When assembled, the rigid frame, and not the wood panels, supports all the external and internal loads of the wine barrel. For introduction of a caramel taste to the wine the wood panels can be initially placed in an oven with the degree of caramelization controlled by the oven temperature and exposure time.

Description:
BACKGROUND  
       [0001]     The background of the invention will be discussed in two parts.  
       Field of the Invention  
       [0002]     The invention relates generally to barrels and other containers in general, and particularly to a rigid framed wine barrel having replaceable wooden panels.  
       Description of the Related Art  
       [0003]     Wine barrels have long been commonly constructed of oak material since the oak wood has been found to provide desirable wine making characteristics such as aiding in the maturing of the wine as well as imparting a distinctive oak and tannin flavoring to the wine. Thus, to produce quality wine that is rich in the oak and tannin taste, winemakers age the wine in oak barrels.  
         [0004]     During the aging process, the wine obtains a suitable amount of oxygen and tannin through the pores of the oak to obtain the desired taste. However, over time the amount of tannin received by the wine from inside of the wood pores is detrimentally decreased eventually requiring replacement of the barrels. Traditional oak barrels having a capacity of 225 liters are generally used only about 2 or 3 times before requiring replacement.  
         [0005]     Thus, since the desired oak flavoring characteristics degrade with repeated use requiring barrel replacement after limited use, this, combined with the rather expensive original cost of oak barrels, has established a need for an alternate wine barrel concept. Attempts have been made to provide alternate wine barrel configurations with the objective of reducing costs and usage of timber, one of which is disclosed in U.S. Pat. No. 4,813,565 issued to Brian J. Croser on 21 Mar. 1989. Croser discloses a wine cask having a circular metal base and a circular metal end cover with a plurality of oak staves arranged circumferentially and lying edge to edge clamped by a circumferential clamp that retains the staves in a cylindrical configuration. A tension clamp extends on an axial direction between the circular metal base and circular metal end cover and clamps the staves between them. While this method permits introduction of oxygen to the wine, it is to a much lesser extent due to the top and bottom metal end plates. Furthermore, this configuration does not lend itself to stacking of the barrels. For instance, if it is desired to stack barrels end to end, problems are created since the wood staves float between the gaskets at each end and if weight is put on these ends the gaskets are compressed. Removal of the weight results in leakage. Further, this type of barrel cannot be rolled during transport because of the clamps on the outside of the barrel.  
         [0006]     Another alternate wine barrel configuration is disclosed in U.S. Pat. No. 5,174,461 issued to Stephen T. Sullivan on 29 Dec. 1992. Sullivan discloses a stainless steel wine barrel body having a circumferential stave holder secured to the inside surface of the barrel for supporting oak staves thereon, with the intention to thereby impart oak characteristics to the wine as it matures. The oak staves are inside of a stainless steel body with one removable end to replace the staves after use. There is a problem in that the stainless steel body will not permit oxygen to be introduced to the wine to augment the aging process and to provide the desirable characteristics to the wine. Thus, stainless steel tanks are not used for quality aging of wine.  
         [0007]     U.S. Pat. No. 5,647,268 issued to Stephen T. Sullivan on 15 Jul. 1997 discloses apparatus for use with standard wine barrels wherein small oak staves are inserted through a bung-hole in the barrel to thereby impart oak characteristics to wine.  
         [0008]     U.S. Pat. No. 5,481,960 issued to Stephen T. Sullivan on 09 Jan. 1996 discloses an infusion tube for use with standard wine barrels for imparting oak characteristics to wine.  
         [0009]     U.S. Pat. No. 5,054,381 issued to DePeaux et al. on 08 Oct. 1991 discloses another wood insertion method for use with standard wine barrels.  
         [0010]     The above related art are illustrative of the various approaches made to satisfy the existing need for different ways of imparting oak characteristics to wine without using the traditional solid oak barrels. However, the related wine barrel concepts remain limited in this regard. The present invention satisfies the existing need by providing a wine barrel having a rigid frame enclosing replaceable uniform oak panels. The panels are straight and symmetrical and after 2 or 3 uses can easily be removed, turned inside out, and replaced within the frame to be used again. This procedure makes better use of the oak wood thereby reducing the barrel cost substantially without compromising quality. Furthermore, once both sides of the wood panels have been used they can be replaced within the rigid frame with new panels. This is relatively easily done without the need for the skilled labor required when making traditional wood barrels.  
         [0011]     Additionally, the load carrying ability of the traditional wood barrel is established by the thickness of the staves. For instance, the traditional 225-liter barrel has appropriate wall thickness to provide adequate oxygen to the wine while providing sufficient load carrying ability to allow stacking of the barrels. Larger barrels require increased thickness for load carrying ability; however, this decreases oxygen passage through the pores of the wood to the wine to the detriment to the wine aging process. The present invention does not have this constraint since the frame, and not the wood panels, carries the load, thus enabling the winemaker to specify wood thickness depending on the amount of oxygen he wishes to introduce to the wine without concern for stacking of the barrels. Also, as constructed, the outside rigid frame does not come in contact with the wine, the wine only in contact with interior oak wood, and once both sides of the wood panels have been exhausted, the frame can be used repeatedly with new wood panels.  
         [0012]     Further, winemakers often introduce a caramel taste to the wine by burning the inside of the traditional barrel during the process of making the barrel. This procedure requires skilled labor to provide the degree of caramelization desired by the winemaker. In contrast, with the present invention the wood panels can be burned in an oven with the degree of caramelization controlled by the oven temperature and time.  
         [0013]     It is thus an aspect of the invention to provide a reduced cost wine barrel assembly having a re-useable rigid barrel frame that eliminates cooperage skill and time that is required to produce traditional barrels.  
         [0014]     It is a further aspect of the present invention to provide a barrel assembly having replaceable oak components in abutting arrangement within a rigid frame sealed in a manner to prevent leakage of the maturing wine.  
         [0015]     It is still further an aspect of the present invention to provide a reduced cost barrel assembly having a re-useable rigid barrel frame that provides varied position stacking strength.  
         [0016]     It is also an aspect of the present invention to provide a barrel assembly having replaceable oak components whereby the wine comes only in contact with the wood of the barrel.  
         [0017]     Other aspects, features and advantages of the invention will become apparent from a reading of the specification, when taken in conjunction with the drawings, in which like reference numerals refer to like elements in the several views.  
       SUMMARY  
       [0018]     In accordance with the present invention there is provided a wine barrel having a rigid reusable frame that reduces cost by eliminating the cooperage skill and time that is required to produce traditional barrels. Assembly of the barrel of the invention is straightforward and requires only minimum tools and skills without the need for the hand-fitting expertise required in constructing a traditional barrel. The rigid reusable frame provides sufficient stacking strength and encloses replaceable wood panels that create a liquid tight container, the wine in the barrel exposed only to wooden surfaces. The panels can be removed from the frame, turned inside out, replaced and reused. They are generally straight and symmetrical and easily constructed with modern machinery having computer controls capable of repeated production of uniform wood panel components. For introduction of a caramel taste to the wine the wood panels can be burned in an oven with the degree of caramelization controlled by the oven temperature and time. The rigid frame is comprised of substantially identical upper and lower ends assembled with rigid connecting bars. Within the connecting bars and upper and lower ends are wood panels assembled to provide the wooden enclosure for the wine. When assembled, the rigid frame, and not the wood panels, supports all the external and internal loads of the wine barrel. The wine only comes in contact with the wood of the barrel. 
     
    
     DRAWINGS  
       [0019]      FIG. 1  is a perspective view of the assembled wine barrel of the invention;  
         [0020]      FIG. 2  is an exploded view of one end and part of the center section of the wine barrel of  FIG. 1 ;  
         [0021]      FIG. 3  is a partially cut away top view of one corner of the wine barrel of  FIG. 1  and with the “U” shape channel partially cut away;  
         [0022]      FIG. 4  is a sectional view of the wine barrel of  FIG. 1  along lines  4 - 4  of  FIG. 3 ;  
         [0023]      FIG. 5  is a sectional view of the wine barrel of  FIG. 1  along lines  5 - 5  of  FIG. 3 ;  
         [0024]      FIG. 6  is illustrates other embodiments of the wine barrel of the invention with the wood end panel and the U-shaped ring removed for clarity;  
         [0025]      FIG. 7  is a sectional view of the wine barrel embodiment of  FIG. 6 ;  
         [0026]      FIG. 8  illustrates the method of achieving a liquid tight barrel with use of tapered wood side panels having tongue and groove joining means;  
         [0027]      FIG. 9  illustrates, enlarged for clarity, the method of achieving a liquid tight barrel wherein the center wood piece is of a wedge shape having tongue and groove joining means;  
         [0028]      FIG. 10  illustrates a circular upper and lower ring to facilitate barrel rolling and another configuration having straight-sided rings to correspond to the number of flat sides of the barrel;  
         [0029]      FIG. 11  illustrates another method of attachment of adjacent wood panels by the use of wedge type metal plates; and  
         [0030]      FIG. 12  is a sectional view of part of  FIG. 11  showing how the ends of the metal plates fit into the wood panel and how to achieve clamping force to provide for a liquid tight barrel. 
     
    
     DESCRIPTION  
       [0031]     Referring to the drawings in general there is illustrated and disclosed a unique wine barrel that reduces costs associated with traditional wine barrels. The wine barrel illustrated and disclosed has a rigid reusable frame; such as of metal that encloses replaceable substantially planar wood panels. The panels can be removed from the frame, turned inside out, replaced and reused or new panels can be installed. Thus, for introduction of a caramel taste to the wine the wood panels can be burned in an oven with the degree of caramelization controlled by the temperature and time in the oven. Usual cooperage skill and time is eliminated, as assembly of the barrel is straightforward requiring only minimum tools and skills. As will be explained, when assembled the frame and not the wood panels support all the external and internal loads of the wine barrel. The frame provides sufficient stacking strength and the wine is exposed only to wooden surfaces. Referring initially to  FIGS. 1-5  and  9 , the rigid framed wine barrel having replaceable planar wooden panels embodying features of the invention will be described.  
         [0032]     For convenience a listing of the reference numerals, in which like reference numerals refer to like elements in the several views, with a brief description of their function, is as follows:  
       Reference Numerals  
       [0000]    
       
           10 . Barrel assembly  
           20 . Channeled U-shaped upper and lower rings  
           21 . Threaded connecting bars to connect upper and lower rings to form a rigid frame.  
           22 . Threaded tie-bolt (six shown)  
           23 . Locating bushing (six shown)  
           24 . Bunghole  
           25 . Upper and lower rectangular wood panels (two shown)  
           25   a.  Upper and lower triangular wood panels (two per end)  
           26 . Side wood panels (two shown)  
           26   a.  Tapered side panel to apply side pressure to adjacent side panels  26   
           27 . Upper and lower gasket  
           28 . Tie rod (two per end)  
           29 . Tie rod nut  
           30 . Groove in each end of wood panels  26  and  26   a    
           31 . Holes drilled in wood panels  25   a  (three in each panel)  
           32 . Holes drilled in upper and lower rings  20  (one for each tie bolt  22 )  
           40 . Connector tubes  
           41 . Extension plate to facilitate frame rigidity when tube type connecting bars used  
           42 . Threaded draw stud  
           43 . Draw stud nut  
           44 . Draw stud-locating bushing  
           45 . Draw stud washer  
           46 . Wood panel  
           47 . Extension plate screw  
           47   a.  Holes for extension plate screw  
           48 . Parallel-sided trapezoid cross sectional wedge (one per side)  
           49 . Plate for wedge  48   
           50 . Wedge bolt for plate  49   
           51 . Wedge bolt nut  
           52 . Tapered wood panel  
           53 . Tapered wood panel  
           70 . Straight sided ring configuration  
           80 . Upper hooked joining plate  
           81 . Lower hooked joining plate  
           82 . Alternate rectangular end wood panels  
           83 . Screws for hooked joining plates  
           84 . Alternate triangular end wood panels  
       
     
         [0070]      FIG. 1  is a perspective elevation view of the wine barrel, generally designated  10 , in accordance with the invention, and  FIG. 2  is an exploded view of the top end and a portion of the center section of the wine barrel  10  of  FIG. 1 . The corresponding lower portion, that is, the bottom end and the remainder of the center section is not shown since, except for the bunghole  24 , the corresponding lower portion is identical such that it would appear as an inverted  FIG. 2 . Thus, as shown or indicated in  FIGS. 1 and 2 , both ends have identical upper and lower U-shaped cross sectional rings  20 , wood end panels  25  and  25   a , tie rods  28 , tie rod nuts  29 , and gaskets  27 . Only the top end is shown with bunghole  24 . Rings  20  are shown U-shaped since this configuration adds strength against buckling and/or twisting of the rings  20 . Other configurations such as a thicker flat plate or an outer L-shaped configuration could be used.  
         [0071]     Briefly, as better illustrated in  FIG. 2 , the wine barrel  10  includes a rigid frame formed of circular upper and lower channeled U-shaped cross sectional rings  20  assembled with threaded connecting bars  21  together with threaded tie-bolt  22  and associated locating bushing  23 . Within this frame of connecting bars  21  and upper and lower rings  20  are upper and lower wood panels  25 ,  25   a  and wood side panels  26 ,  26   a.  As shown more clearly in  FIG. 9  and explained below, wood panel  26   a  is wedge-shaped and panels  26  are configured to evenly and abuttingly accept panel  26   a  under pressure.  
         [0072]     Connecting bars  21  are attached to U-shaped cross sectional rings  20  and end panels  25   a  by means of locating bushing  23  and tie-bolts  22 . Connecting bars  21  are shown in hexagonal configuration but may be of other suitable configuration. As will be further explained below, in assembly of the barrel  10 , and after the upper and lower ends are assembled, side panel members  26  are placed in position against the connecting bars  21 . The tapered wedge shaped panel  26   a  is then placed in position resting against the angled sides of the corresponding side panel  26 . Then, with the aid of locating bushings  23  and threaded tie-bolts  22 , the gaskets  27 , wood panels  25 ,  25   a  and U-shaped cross sectional rings  20  are fitted to the connecting bars  21 . Threaded tie-bolts  22  are then tightened to press the wood side panels  26   a  downward against adjacent side panels  26  and against the upper and lower wood panels  25 ,  25   a  thereby to provide a liquid tight barrel.  
         [0073]      FIG. 3  is a partially cut away top view of one corner of the wine barrel of  FIG. 1  illustrating fitting of the connection bars  21 , the wood side panels  26 ,  26   a , and the upper gasket  27  as it fits into the grooves  30  of wood panels  26 ,  26   a.  The U-shaped circular cross sectional ring  20  is also shown partially cut away.  
         [0074]      FIG. 4  is a sectional view of the wine barrel  10  taken along lines  4 - 4  of  FIG. 3 . Taken through the center of the connecting bar  21 , illustrated is the manner in which triangular wood panels  25   a  are mounted to wood panels  26 ,  26   a  by means of tie bolt  22  screwing into connecting bar  21  by way of locating bushing  23  and U-shaped ring  20 . A portion of gasket  27  showing how it is compressed against wood panels  26 ,  26   a  is also shown.  
         [0075]      FIG. 5  is an elevation sectional view of the wine barrel  10  taken along lines  5 - 5  of  FIG. 3 . Illustrated is the manner in which gasket  27  is trapped within the ends of the wood panels  26 ,  26   a,  and how the assembled wood panels  25 ,  25   a  overlay gasket  27  and cooperate with the “U” shaped cross sectional ring  20  to form a rigid strong frame assembly. The ends of the side panels  26 ,  26   a  have grooves  30  for trapping a portion of the gasket  27  therein, the depth of the grooves  30  determinative of the amount of pressure that can be applied to the gasket  27  during assembly of barrel  10 . The depth of the groove  30  therefore controls the amount of reduction in thickness the gasket  27  will receive when upper and lower wood panels  25 ,  25   a  are pressed against the ends of the side panels  26 ,  26   a.  The combination of the pressure fit of panel  26   a  with panels  26 , and of panels  25 , 25   a  with  26 ,  26   a  provides for a liquid tight barrel.  
         [0076]     As explained above, in assembly of barrel  10  the two end plates are first assembled into a framework using connecting bars  21 , after which side wood panel members  26 ,  26   a  are fitted within the resulting framework. The barrel  10  is then securely assembled by means of locating bushings  23  and associated nut  24 .  
         [0077]     In sequence, one end comprised of a ring  20 , wood panel&#39;s  25 ,  25   a,  threaded tie bolts  28  and associated tie rod nuts  29 , and gasket  27  is assembled. First, wood panels  25 ,  25   a,  which have been machined with tongue and groove ends, are joined after which they are secured by threaded tie rods  28  and associated tie rod nuts  29 , tie rods  28  having been placed through previously drilled holes (not shown) in wood panels  25 ,  25   a.  The assembled end plate is then placed on an inverted U-shaped cross sectional ring  20  and locating bushings  23  are placed into the corresponding holes  31 . The connecting bars  21  are next attached to the lower assembled wood panels  25 ,  25   a  and ring  20  using tie bolts  22  and locating bushings  23  with the bars  21  pointing upward.  
         [0078]     The lower gasket  27  is then fitted atop the assembled wood panels  25 ,  25   a  within the connecting bars  21  land side panel members  26 ,  26   a  are placed in position above the lower gasket  27  and against the connecting bars  21 . The tapered wedge-shaped panel  26   a  is placed in position between the angled sides of the two panels  26 , the upper end of panel  26   a  being somewhat higher than the ends of panels  26  in the absence of downward pressure to panel  26   a.  The upper gasket  27  is placed over the side panels and into the grooves  30 . The upper assembled wood panels  25 ,  25   a  and U-shaped cross sectional ring  20  are then positioned in place with the aid of locating bushings  23 . Tie-bolts  22  are next engaged and evenly tightened until the wedge-shaped panel  26   a  is moved downward to press against the panels  26  to become level with panels  26 . At this time the upper ends, side panels  26 ,  26   a,  and wood panels  25 ,  25   a,  cooperate to create a liquid tight barrel.  
         [0079]      FIG. 6  illustrates another embodiment of the wine barrel  10  in accordance with the invention wherein a wooden wedge  48  having a trapezoid cross section is compressed between adjacent wood panels  46  and thus expands against panels  46  to create a liquid tight barrel. The wedge  48  is compressed between adjacent wood panels  46  with coaction by wedge plate  49 , wedge bolt  50  and wedge nut  51 , all of stainless steel.  FIG. 6  further indicates the use of round stainless steel tubes  40  for connecting the top and bottom wooden panels  25 ,  25   a  and U-shaped cross sectional rings  20 . This embodiment is further shown and described in  FIG. 7 .  FIG. 6  also illustrates extension plate  41  used to augment rigidity of the barrel frame when tube connecting bars  40  are used. The wedge  48  and tube  40  embodiments are both illustrated in  FIG. 6 ; however, they may be used in separately embodiments as may be desired. It is to be understood that although stainless steel is intended to be specified wherein wine may come in contact with other than wood, other suitable material that is non-reactive to wine may also be used.  
         [0080]      FIG. 7  is a sectional view taken through the center of the tube  40  and of side wood panels  46  of the embodiment of  FIG. 6 . Shown is tube  40 , extension plate  41 , threaded draw stud  42 , draw stud nut  43 , draw stud locating bushing  44 , and draw stud washer  45 . In assembly, each tube  40  has a draw stud  42  inside and is assembled essentially as were connecting bars  21  as previously described. Draw stud locating bushings  44  are inserted through the U-shaped cross sectional ring  20  and wood panels  25   a , and into tubes  40  after which the frame is tightened using draw stud washer  45  and draw stud nut  43 . Extension plate  41  is affixed to the underside of wood panel  25   a  by fitting extension plate screws  47  through extension plate holes  47   a.    
         [0081]      FIG. 8  illustrates an alternate method of achieving a liquid tight barrel with use of tapered wood panels  52  and  53  that have tongue and groove joining means. When the rigid frame is tightened these panels exert side pressure as indicated against the connecting means of the frame thereby achieving a liquid tight barrel.  
         [0082]      FIG. 9  illustrates more clearly the method of achieving a liquid tight barrel wherein the center wood piece  26   a  has a wedge shape as previously discussed. When the frame is tightened wood piece  26   a  is pressed downward and exerts side pressure against adjacent panels  26  as indicated; these panels tapered to accept wedge shaped wood piece  26   a.    
         [0083]      FIG. 10  illustrates alternate configurations for the upper and lower barrel rings. The circular configuration  20  facilitates rolling of the barrel during transportation. The straight-sided configuration  70  has sides corresponding in number to the number of flat sides selected for the barrel. Six sides are shown in the figure.  
         [0084]      FIG. 11  is a top view of another method of end plate assembly using stainless steel joining plates  80  to hold the wood pieces  82 ,  84  together. Similar lower stainless steel metal plates  81  are attached underneath the panels  82 ,  84  as shown in  FIG. 12 .  
         [0085]      FIG. 12  is a sectional view of the assembly method of  FIG. 11  illustrating the hooked configuration of the upper and lower stainless steel metal plates  80 ,  81 , and how tongue and groove panels  82 ,  84  can be used to assemble an end plate.  
         [0086]     In accordance with the above, there has been shown and described an improved wine barrel assembly having a re-useable rigid frame and replaceable oak components therein. While the invention has been described in connection with embodiments thereof, it is obvious that various modifications and changes can be made within the spirit and scope of the invention.