VENTED PROMOTIONAL COMPARTMENT

Abstract: An improved housing (300) for the delivery of a promotional element within a closure of a beverage container. The housing includes a promotional compartment (310) for containing the promotional element. The promotional compartment (310) is sealed by membrane (400) with a plurality of vent holes (420). The vent holes (420) may have diameters of about 0.001 to 0.01 inches.

Description: VENTED PROMOTIONAL COMPARTMENT Technical Field The present invention relates generally to a promotional compartment for use within the closure of a beverage container and more particularly relates to a promotional compartment having a membrane with specially located and/or specially sized vent holes for use with beverages such as carbonated soft drinks. Background of the Invention A known promotional concept for carbonated and other beverages is to enclose a promotional element within the closure of the beverage container. This promotional element may include a coupon, currency, or some type of game piece. Known promotion delivery designs may include a container closure with a promotional compartment positioned therein. The compartment is removed from the closure upon the opening of the container. The promotional element is then removed from the compartment by the consumer. Known closure/compartment arrangements are shown in, for example, U.S. Patent No. 5,056,659 and U.S. Patent No. 5,524,788, the disclosures of which are incorporated herein by reference. When a promotional compartment is used with a beverage container, the compartment must isolate the promotional element and provide a liquid-tight seal to prevent contact between the beverage and the promotional element. If the promotional compartment is used with a carbonated beverage container, carbon dioxide gas in the headspace of the container will permeate into the promotional compartment once the container is sealed. The gas will permeate into the compartment until the pressure reaches equilibrium with the gas pressure in the container headspace. After the container is opened, the promotional compartment will remain pressurized unless the compartment is vented in some fashion. Failure to vent the promotional compartment could result in loss of compartment integrity. Further, "doming" of the plastic membrane could occur and cause the compartment to dislodge from the closure during closure removal. Known venting methods include a self-delaminating membrane shown in U.S. Patent No. 5,819,976, the disclosure of which is incorporated herein. Other known methods include radial vents that are formed by relieving the seal between the membrane and the prize compartment in specific areas. A further method includes the use of mechanically formed vent holes in the membrane. The main drawback with the self-delaminating membranes and the radial vents is poor venting consistency. The main drawback with the mechanically formed vent holes is that slight membrane tearing can occur. This tearing can increase the chance that any stray droplets of the beverage that settle on the membrane may pass through the vent holes and contact the promotional element. If a stray droplet of beverage contacts the promotional element, consumers might be dissatisfied or question product quality. Actual product quality, however, would be unaffected because the promotional compartment already has been removed from the closure and the beverage container. What is needed therefore is a promotional compartment that vents consistently and keeps stray droplets of beverage from contacting the promotional element. These goals must be accomplished in a promotional compartment that fits within typical beverage container closures in a cost-effective manner. Summary of the Invention The present invention provides for an improved housing for the delivery of a promotional element within a closure of a beverage container. The housing includes a promotional compartment for containing the promotional element. The promotional compartment is sealed by a membrane with a plurality of vent holes. The vent holes may have diameters of about 0.001 to 0.015 inches. Diameters of about 0.001 to about 0.005 inches are preferred Specific embodiments of the invention include the use of a promotional compartment with a circumferential flange and a cylindrical sidewall. An outward step is positioned between the cylindrical sidewall and the circumferential flange so as to define an annular recess. The plurality of vent holes may align with, or be positioned slightly outboard of, the annular recess. The vent holes may have diameters of about 0.001 to 0.015 inches when aligned with or slightly outboard of the annular recess. The vent holes also may be positioned substantially across all or part of the membrane of the promotional compartment. The vent holes may be manufactured by laser drilling. The membrane is heat sealed or otherwise bonded to part or all of the circumferential flange. The membrane may be a gas permeable material such as a PET or polyethylene. The membrane may have a thickness of about 0.002 inches. The membrane covers all or part of the circumferential flange, the annular recess, and the promotional compartment. The method of the present invention provides for the delivery of a promotional element to a carbonated beverage consumer. The method includes the steps of inserting a promotional element within a promotion housing, sealing the promotion housing with a membrane having a plurality of vent holes with diameters of about 0.001 to 0.01 inches, inserting the promotional housing within a beverage closure, sealing a carbonated beverage container with the closure, penetrating the promotional housing with gasses from the carbonated beverage until the pressure within the container and the promotional housing reaches equilibrium, opening the beverage container, and releasing the penetrated gasses from within the promotional compartment through the vent holes. The method of the present invention may further include the step of manufacturing the vent holes by laser drilling and the step of removing the promotional element from the promotion housing without droplets of the beverage contacting the promotional element. Another method of the present invention provides for the delivery of a promotional element to a carbonated beverage consumer. The method includes the steps of drilling a plurality of vent holes in a membrane with a laser, inserting a promotional element within a promotion housing, sealing the promotion housing with the membrane, inserting the promotion housing within a closure of a beverage container, delivering the beverage container to the consumer, opening the beverage container, and removing the promotional element from the promotion housing without droplets of the beverage contacting the promotional element. The vent holes may have diameters of about 0.001 to 0.01 inches. The vent holes have diameters large enough to allow the penetration of gasses therethrough but small enough to prevent the passage of liquid therethrough. The laser may be a carbon dioxide laser with a variable power output. The pulse duration of the drilling step may be about 0.0003 seconds. A further method of the present invention provides for the use of a gas permeable and liquid impermeable membrane. The method includes the steps of drilling a plurality of vent holes in the membrane with a laser, sealing a housing with the membrane, covering the membrane with fluid droplets, and preventing the penetration of the membrane by the fluid droplets by sizing the plurality of vent holes so as to have diameters large enough to allow the penetration of gasses therethrough and small enough to prevent the passage of liquid therethrough based upon the surface tension of the droplets. Brief Description of the Drawings Fig. 1 is a cross-sectional view of a known closure and promotional compartment design. Fig. 2 is a cross-sectional view of another known closure and promotional compartment design. Fig. 3 is a plan view of a known closure and promotional compartment design. Fig. 4 is a cross-sectional view of the promotional housing of the present invention. Fig. 5 is a plan view of the membrane and the promotional housing of the present invention. Fig. 6 is a plan view of an alternative membrane of the present invention. Fig. 7 is a plan view of the alternative membrane and an alternative promotional housing of the present invention. Fig. 8 is a plan view of the alternative membrane and an alternative promotional housing of the present invention. Detailed Description of the Invention Referring now in more detail to the drawings, in which like numerals refer to like elements throughout the several views, Figs. 1-3 herein show several known closure and promotional compartment designs 100. These closure and promotional compartment designs 100 generally include an outer closure 110 having a circular top portion 120 and an annular skirt portion 130. The annular skirt portion 130 includes an internal helical thread formation 140 for cooperative engagement with a mating thread formation 150 of an associated beverage container 160. The closure and promotional compartment designs 100 also include a promotional compartment 170. The promotional compartment 170 generally has a cup-shaped configuration with a circular bottom wall 180 and a cylindrical sidewall 190 extending upwardly from the bottom wall 180. A promotional element 185 is positioned within the promotional compartment 170. The promotional compartment 170 also may have a pull tab 200 to facilitate the opening of the promotional compartment 170 by a consumer. The design of several embodiments of the pull- tab 200 are described in U.S. Patent Nos. 5,915,585 and 6,032,820, both entitled "Easy-Open Promotional Compartment," the disclosure of which are incorporated herein. The promotional compartment 170 also includes an annular flange 210 that extends generally horizontally from the upper edge of the cylindrical sidewall 190. The annular flange 210 assists in securing the promotional compartment 170 firmly within the closure 110 as described in detail below. The closure 110 and the promotional compartment 170 may be molded or formed from a polyethylene plastic or from similar types of thermoplastic materials. As is shown if Fig. 3, the promotional compartment 170 is enclosed by a cover member 220. The cover member 220 may be a membrane-like layer that is fixedly attached to the annular flange 210. The cover member 220 may be, for example, a laminate of low-density polyethylene with PET (polyethylene terephthalate). The cover member 220 may include a circular vent hole 230 positioned largely in the middle of the promotional compartment 170. The use of the cover member 220 results in the slow migration of pressurized gasses into the promotional compartment 170 when the beverage container 160 is sealed while the vent hole 230 allows for the fast escape of the pressurized gasses from the promotional compartment 170 when the beverage container 160 is opened. The vent hole 230 may have a diameter of about 0.015 inches or greater. The vent hole 230 also may be distorted in the manufacturing process. Such a size, however, may permit fluid droplets to penetrate through the cover member 220, especially if slight tearing occurs at the edges of the vent hole 230 due to the forming method. The promotional compartment 170 of Fig. 1 is positioned within the closure 110 adjacent to an inner liner 240. The inner liner 240 extends beneath the circular top portion 120 of the closure 110 and engages the annular flange 210 of the compartment 170. The annular flange 210 is positioned and secured within a lip element 250 surrounding the liner 240. The liner 240 may be molded in place or may be a preformed component that is inserted mechanically within the closure 110. A preformed liner 240 configuration with the use of the lip 250 is shown in U.S. serial number 882,395 described above. Alternatively, the promotional compartment 170 of Fig. 2 is a combination of an inner liner 260 positioned within the closure 110 and an extended mating portion 270 of the annular flange 210. The liner 260 may be molded in place or may be a preformed disk that is inserted mechanically inserted within the closure 110. The extended mating portion 270 of the annular flange 210 extends to the inner sidewall of the closure 110 and is held in place by a retention bead 280 positioned along the thread formations 140 of the outer closure 110. The respective liners 240, 260 of both Figs. 1 and 2 therefore assist in sealing the beverage container 160 and also permit the venting of gases from the promotional compartment 170. Specifically, the known closure and promotional compartment designs 100 described herein allow for the escape of pressurized gasses through the vent hole 230 and then along the respective liners 240, 260. Fig. 4 shows a promotional housing 300 of the present invention. The promotional housing 300 includes a cup-shaped promotional compartment 310 defined by a cylindrical sidewall 320 and a circular bottom floor 330. The cylindrical sidewall 320 extends vertically from the circular horizontal floor 330. It is important to note that the use of the terms "vertical" and "horizontal" herein is meant to describe the relative positions of the elements with respect to each other rather than an actual or absolute orientation. The cylindrical sidewall 320 also may include a pull-tab 340 to assist in opening the promotional compartment 310. The pull-tab 340 may be similar or identical in design to the pull-tab 200 described above. The promotional housing 300 also may include the sealing liners 240, 260 and other closure and sealing elements similar to those described above with respect to Figs. 1 and 2. The cylindrical sidewall 320 leads to an outward step 350 at its top edge. The outward step 350 first extends horizontally away from the cylindrical sidewall 320 to form a bottom member 354 and then vertically upward and parallel to the cylindrical sidewall 320 to form a side member 356. The cylindrical sidewall 320 extends vertically above the bottom member 354 of the outward step 350 to form an annular ring 360. The bottom member 354 and the side member 356 of the outward step 350 and the annular ring 360 combine to define an annular recess 370. The annular recess 370 is intended to prevent the penetration of fluid into the promotional compartment 310. The side member 356 of the outward step 350 also leads to a circumferential flange 380. The circumferential flange 380 extends horizontally away from the side member 356 and the cylindrical sidewall 320. A membrane layer 400 is attached to the circumferential flange 380. The membrane 400 may be heat sealed to the flange 380. Alternatively, other conventional sealing methods may be employed. As is shown in Fig. 5, the membrane 400 has a plurality of vent holes 410 that can align with the annular recess 370 positioned above the outward step 350. Similarly, the vent holes 410 may be positioned slightly outboard of the annular recess 370 if the membrane 400 is not adhered or heat sealed to the flange 380 in that area. The vent holes 410 allow pressurized gasses to escape from the promotional compartment 310. The membrane 400 may be made from a gas permeable material such a polyethylene. Specifically, a laminate of low-density polyethylene with PET (polyethylene terephthalate) may be used. The membrane 400 may be about 0.001 to 0.005 inches in thickness, with about 0.002 inches preferred. The vent holes 410 may be created within the membrane 400 before the membrane 400 is attached to the promotional housing 300. In this scenario, the vent holes 410 may be made in a continuous fashion along a web 405 of the membrane 400 so as to align with, or slightly outboard of, the annular recess 370 or in any other desired configuration. Alternatively, the vent holes 410 may be created after the membrane 400 is fixedly attached to the promotional housing 300. A laser drilling method may used to create the vent holes 410. Laser drilling offers the opportunity to make the vent holes 410 with much smaller diameters than is generally possible with most mechanical methods. For example, the vent holes 410 may have diameters of about 0.001 to 0.01 inches or less. Diameters of about 0.001 to about 0.005 inches are preferred. An acceptable laser for creating the vent holes 410, 420, for example, would be a computer-controlled low flowing carbon dioxide gas laser with a variable power output of about 25 to 225 watts. The power level would be approximately ninety-two percent (92%). The pulse duration would be approximately 0.0003 seconds with a maximum transverse speed of about 200 feet per minute. A beam splitter also may be used to permit two (2) or more rolls of the membrane 400 material to be drilled simultaneously. The diameters of the vent holes 410 described herein have proven large enough to vent pressurized gasses from within the promotional compartment 310 but also are small enough to restrict substantially the penetration of liquid droplets therethrough. The vent holes 410 largely prevent the penetration of the liquid droplets therethrough due to the surface tension of the liquid with respect to the diameter of the vent holes 410. The vent holes 410 therefore provide protection from fluid droplets penetrating therethrough when the fluid is resting statically on top of the membrane 400. (The vent holes 410, however, may not provide protection against seepage of fluid under a driving pressure.) Further, the vent holes 410 may be aligned over the annular recess 370 so as to allow pressurized gasses to escape while also trapping any fluid that does penetrate through the membrane 400 within the annular recess 370. Alternatively, the vent holes 410 may be positioned outboard of the annular recess 370 if the membrane 400 is not adhered to the flange 380 in that area. The vent holes 410 also may be positioned across the entire membrane 400, including across the promotional compartment 310 and the circumferential flange 380. As is shown in Fig. 6, a plurality of vent holes 420 may be positioned across all or part of the entire web 405 of the membrane 400 such that the vent holes 420 cover all or part of the promotional compartment 310. Again, the small diameters of the vent holes 420 allow the escape of pressurized gasses when the beverage container 160 is opened while preventing fluid droplets from seeping into the promotional compartment 310 when the promotional housing 300 is removed from the closure 110. In the embodiment shown in Fig. 7, the use of the annular recess 370 may not be required. Rather, the plurality of the vent holes 420 positioned over the entire promotional compartment 310 provides adequate venting of the pressurized gasses while also preventing the penetration of the membrane 400 by the beverage droplets. The vent holes 420 with the size as described herein do not require any particular placement on the membrane 400. The diameters of the vent holes 420 are small enough to prevent substantially the penetration of fluid therethrough based upon surface tension. The vent holes 410, 420 in Figs. 5-7 are shown for the purpose of example only. The vent holes 410, 420 are not intended to be drawn to scale. A further embodiment is shown in Fig. 8. In this example, a plurality of vent holes 430 are positioned over the annular recess 370 or outboard of this region. These vent holes 430 are not limited in diameter as described above. Rather, these vent holes 430 may have large diameters of about 0.005 to 0.015 inches or greater. Although more beverage droplets may penetrate through the membrane 400 because of the size of the vent holes 430 as opposed to the size of the vent holes 410, 420, the annular recess 370 serves as a basin to capture any such droplets. Again, the vent holes 4300 in Fig. 8 are shown for the purpose of example only. The vent holes 430 are not intended to be drawn to scale. Tests comparing the original closure and promotional compartment designs 100 with the improved promotional housing 300 show that the venting time is similar and satisfactory while the improved promotional housing 300 adequately prevents the penetration of liquid droplets. For example, the use of the membrane 220 made of PET with low density polyethylene and having about 0.002 inches in thickness and one (1) vent hole 230 of approximately 0.015 inches in diameter will generally vent from an initial pressure of about seventy (70) psi to about thirty-five (35) psi in about 105 milliseconds and from about thirty-five (35) psi to about zero (0) psi in about 110 to about 310 milliseconds. The use of a similar membrane 400 with seven (7) to nine (9) vent holes 410 positioned about 0.687 inches apart would vent from about seventy (70) psi to about thirty-five (35) psi in about 110 milliseconds and from about thirty-five (35) psi to about zero (0) psi in about 410 to about 610 milliseconds. These latter venting rates are adequate to vent the promotional compartment 310 without damage to the promotional housing 300. In use, the promotional element 185 of some sort is inserted within the promotional compartment 310 of the improved promotional housing 300. The membrane 400 is then heat sealed or otherwise attached in whole or in part to the circumferential flange 380 so as to seal the promotional compartment 310. The improved promotional housing 300 is then positioned within the closure 110. The closure 110 then encloses and seals the beverage container 160. In the case of a carbonated soft drink, the beverage container 160 may contain a fluid sealed at a pressure of about fifty-five (55) psi with about four (4) volumes of carbon dioxide. Over time, the gas pressure within the beverage container 160 will seek equilibrium with the partial pressure within the promotional compartment 310. Because the compartment sidewall 320 and bottom floor 330 are made from a substantially gas permeable material, carbon dioxide and the other gasses from the carbonated beverage within the beverage container 160 will penetrate into the promotional compartment 310 until the pressure therein reaches equilibrium. When the consumer opens the beverage container 160, the carbon dioxide and other gasses within the container 160 rush out under pressure. The pressure within the beverage container 160 immediately drops from its sealing pressure of, for example, fifty-five (55) psi to atmospheric pressure. The carbon dioxide and other gasses within the promotional compartment 310, however, cannot immediately evacuate like the gasses within the beverage container 160. Rather, the gasses within the promotional compartment 310 exit via the vent holes 410, 420 of the membrane 400. Specifically, the gasses pass through the vent holes 410, 420, across the liner 240, 260, and down along the circular side walls 320, 130 and the respective threads 140, 150 of the closure 110 and the beverage container 160. The consumer then removes the improved promotional housing 300 from the closure 110. In the process, any droplets of beverage fluid that may be trapped, for example, about the pull-tab 340 and flow onto the membrane 400 cannot pass through the vent holes 410, 420 because of the surface tension of the fluid. Further, any fluid that does penetrate through the membrane 400 is trapped within the annular recess 370 if the vent holes 410, 420 are located thereon or adjacent thereto. The consumer then pulls the pull-tab 340 to open the promotional compartment 310. The promotional element 185 is then removed and the promotional compartment 310 may be discarded. The manner in which the vent holes 430 are used is similar. Any droplets of beverage fluid that may be trapped, for example, about the pull-tab 340 and flow onto the membrane 400 generally cannot pass through the vent holes 430 because of the surface tension of the fluid. Any fluid that does penetrate through the membrane 400 is trapped within the annular recess 370 because the vent holes 430 are located thereon or adjacent thereto.

Claims: CLAIMS We claim: 1. An improved housing for the delivery of a promotional element within a closure of a beverage container, comprising: a promotional compartment for containing said promotional element; and a membrane for sealing said promotional compartment; said membrane comprising a plurality of vent holes comprising diameters of about 0.001 to 0.015 inches. 2. The improved housing for the delivery of a promotional element of claim 1, wherein said promotional compartment comprises a circumferential flange. 3. The improved housing for the delivery of a promotional element of claim 2, wherein said promotional compartment comprises a cylindrical sidewall. 4. The improved housing for the delivery of a promotional element of claim 3, wherein said promotional compartment comprises an outward step positioned between said cylindrical sidewall and said circumferential flange. 5. The improved housing for the delivery of a promotional element of claim 4, wherein said outward step comprises an annular recess. 6. The improved housing for the delivery of a promotional element of claim 5, wherein said plurality of vent holes aligns with said annular recess. 7. The improved housing for the delivery of a promotional element of claim 5, wherein said plurality of vent holes aligns slightly outboard of said annular recess. 8. The improved housing for the delivery of a promotional element of claim 5, wherein said plurality of vent holes comprises a line of said vent holes positioned adjacent to said annular recess. 9. The improved housing for the delivery of a promotional element of claim 2, wherein said membrane comprises a heat seal with said circumferential flange. 10. The improved housing for the delivery of a promotional element of claim 1, wherein said membrane comprises a gas permeable material. 11. The improved housing for the delivery of a promotional element of claim 1, wherein said membrane comprises a polyethylene material. 12. The improved housing for the delivery of a promotional element of claim 1, wherein said membrane comprises a thickness of about 0.002 inches. 13. The improved housing for the delivery of a promotional element of claim 1, wherein said plurality of vent holes is positioned substantially across a web of said membrane. 14. The improved housing for the delivery of a promotional element of claim 1, wherein said plurality of vent holes is positioned substantially across all of said promotional compartment. 15. The improved housing for the delivery of a promotional element of claim 1, wherein said plurality of vent holes are manufactured by laser drilling. 16. The improved housing for the delivery of a promotional element of claim 5, wherein said membrane covers part of said circumferential flange and all of said annular recess. 17. The improved housing for the delivery of a promotional element of claim 1, wherein said plurality of vent holes comprising diameters of about 0.001 to 0.005 inches. 18. The improved housing for the delivery of a promotional element of claim 1, wherein said plurality of vent holes comprising diameters of about 0.001 to 0.01 inches. 19. A method for the delivery of a promotional element to a carbonated beverage consumer, comprising the steps of: drilling a plurality of vent holes in a membrane with a laser; inserting a promotional element within a promotion housing; sealing said promotion housing with said membrane; inserting said promotional housing within a closure of a beverage container; delivering said beverage container to said consumer; opening said beverage container; and removing said promotional element from said promotion housing without droplets of said beverage contacting said promotional element. 20. The method of claim 19, wherein each of said plurality of vent holes comprises diameters of about 0.001 to 0.01 inches. 21. The method of claim 19, wherein said laser comprises a carbon dioxide laser with a variable power output. 22. The method of claim 19, wherein said drilling step comprises a pulse duration of about 0.0003 seconds. 23. The method of claim 19, wherein said plurality of vent holes comprises diameters large enough to allow the penetration of gasses therethrough. 24. The method of claim 19, wherein said plurality of vent holes comprise diameters small enough to prevent the passage of liquid therethrough.

Inventors: LADINA JOSEPH M, RULE MARK, LADINA, JOSEPH, M., RULE, MARK
Applicants: COCA COLA CO, THE COCA-COLA COMPANY
Application year: 2000
Main classification: B65D51
IPC codes: B65D51