Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
ECO-FRIENDLY LIQUID CONTAINER
Cross-Reference to Related Applications
[0001] This application claims priority to U.S. Provisional Application
61/718,186 filed on October 24, 2012.
Background of the Invention
[0002] The present subject matter relates generally to eco-friendly
liquid
packaging containers.
[0003] Currently, the world uses approximately 200,000,000,000 plastic
bottles and roughly the same number of aseptic package containers a year.
Worldwide, on average, only 15% of the plastic bottles are recycled. Further,
recycled bottles in the USA account for only 20-29% of the total recycled
material
according to the American Plastics Council. The non-recycled bottles end in
landfills
or as uncollected litter.
[0004] For every one ton of plastic that is recycled or reduced, roughly
2 tons
of carbon dioxide emissions are saved. One ton of recycled plastic saves 5,774
kilowatts of electricity and 685 gallons of oil according to the U.S. House
Select
Committee on Energy Independence and Global Warming. In addition, replacing
3,700 polyethylene terephthalate (PET) bottles, a popular plastic used in
bottles,
saves one barrel of petrol.
[0005] Notwithstanding attempts to reduce the amount of plastic used in
plastic bottles, the average 16 ounce (oz.) plastic bottle weighs
approximately
16 grams. The lightest available 16 oz. plastic bottle weighs approximately
9.2
the shrink-wrap film secures the lid to the housing.
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grams. However, such a light plastic bottle requires expensive equipment to
produce.
[0006] Accordingly, there is a need for a new product that is a sustainable
and eco-friendly solution that helps lessen the environmental impact of
packaging
beverages. In addition, there is a need for a product that decreases the
greenhouse
effect, reduces the need for more landfill space, and uses mostly renewable
materials. The product needs to be easily mass-produced, require a small
investment and production space, have a production that may be scalable, and a
competitive price with the standard plastic bottles and other liquid container
packages.
Brief Summary of the Invention
[0007] The present disclosure provides an eco-friendly liquid container for
non-carbonated liquids. Various examples of the container are provided herein.
[0008] The disclosed liquid container is made predominantly from a paper
housing, a thin plastic lid, and a single layer of shrink-wrap film, thereby
resulting in
a container that uses up to 70% less plastic and non-recyclable materials than
conventional plastic bottles. In addition to being environmentally friendly,
the
reduction in materials is also cost effective and results in a product that
weighs less
than conventional beverage containers. In one example, the liquid container
only
uses 5.5 grams of plastic.
[0009] The present disclosure provides a container comprising a housing
including a side wall, a housing first end, and a housing second end. The
container
also contains a flexible storage bag within the housing, and a lid positioned
over the
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housing first end, wherein at least a portion of the flexible storage bag is
held
between the lid and the housing first end. In addition, the container includes
a
shrink-wrap film surrounding at least a portion of the housing and at least a
portion
of the lid, wherein the shrink-wrap film secures the lid to the housing.
[0010] The container may further include at least one tab extending from
the
housing second end, wherein the at least one tab defines a bottom plane
perpendicular to the side wall. The shrink-wrap film may surround at least a
portion
of the at least one tab, wherein the at least one tab and the shrink-wrap film
retain
the bottom panel within the housing along the bottom plane.
[0011] The housing may be formed from a single sheet of paper. In an
example, the housing is made of a foldable cardboard. In addition, the cross-
sectional shape of the housing may be an octagon.
[0012] In an example, at least two portions of the flexible storage bag
are
secured between the lid and the housing first end. The flexible storage bag
may be
made of a polymeric material. Further, the lid may include an opening
providing
access to the flexible storage bag.
[0013] The container may also include a straw releasably connected to an
outer surface of the shrink-wrap film or the housing, wherein the straw is
configured to puncture through the shrink-wrap film and the flexible storage
bag
[0014] In an example, the container may include a liquid within the
flexible
storage bag, wherein the amount of liquid is less than the storage capacity of
the
flexible storage bag.
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[0015] The present disclosure also provides a method of forming a
container,
wherein the method comprises forming a housing including a side wall, a
housing
first end, and a housing second end, and inserting a flexible storage bag into
the
housing. The method also includes placing a lid over the housing first end
wherein
the lid secures at least a portion of the flexible storage bag between the
housing first
end and the lid, and securing the lid to the housing by heat sealing a shrink-
wrap
film around at least a portion of the housing and at least a portion of the
lid.
[0016] The container may further include at least one tab extending from
the
housing second end, wherein the at least one tab defines a bottom plane
perpendicular to the side wall. The shrink-wrap film may surround at least a
portion
of the at least one tab, wherein the at least one tab and the shrink-wrap film
retain
the bottom panel within the housing along the bottom plane.
[0017] The housing may be formed by folding a single sheet of paper. In an
example, the housing is made of a foldable cardboard. Further, the cross-
sectional
shape of the housing may be an octagon.
[0018] The flexible storage bag may be made of a polymeric material. In an
example, at least two portions of the flexible storage bag are secured between
the lid
and the housing first end. Further, the flexible storage bag may include a
liquid,
wherein the amount of liquid is less than the storage capacity of the flexible
storage
bag.
[0019] In an example, the lid includes an opening providing access to the
flexible storage bag. The method may include releaseably attaching a straw to
an
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outer surface of the heat sealed shrink-wrap film, wherein the straw is
configured to
puncture through the shrink-wrap film and the flexible storage bag.
[0020] An advantage of the present container and method decreasing the
environmental impact of packaging liquids.
[0021] A further advantage of the present container and method is reducing
greenhouse emissions and landfill space compared to conventional plastic
bottles.
[0022] Another advantage of the present container and method is providing a
cost effective manufacturing process for packaged liquids.
[0023] Additional objects, advantages and novel features of the examples
will be set forth in part in the description which follows, and in part will
become
apparent to those skilled in the art upon examination of the following
description
and the accompanying drawings or may be learned by production or operation of
the examples. The objects and advantages of the concepts may be realized and
attained by means of the methodologies, instrumentalities and combinations
particularly pointed out in the appended claims.
Brief Description of the Drawings
[0024] The drawing figures depict one or more implementations in accord
with the present concepts, by way of example only, not by way of limitations.
In the
figures, like reference numerals refer to the same or similar elements.
[0025] Fig. 1 is a perspective view of an embodiment of the container
disclosed herein.
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[0026] Fig. 2A is a perspective view of an example of the flexible storage
bag
positioned inside the housing with a portion of the flexible storage bag on
the outer
surface of the housing.
[0027] Fig. 2B is a perspective view of an example of the lid positioned
over
the housing first end, wherein a portion of the flexible storage bag is held
between
the lid and the housing first end.
[0028] Fig. 2C is a perspective view of an embodiment of the container,
wherein the shrink-wrap film secures the lid to the housing.
[0029] Fig. 3 is an exploded view of an example of the container.
[0030] Fig. 4 is a bottom perspective view of the housing including tabs,
wherein the bottom panel is leaning against the side wall of the housing.
[0031] Fig. 5 is a top perspective view of the bottom panel being pushed
through the housing toward the bottom plane.
[0032] Fig. 6 is a bottom perspective view of the housing including tabs,
wherein the bottom panel is in contact with the tabs in the bottom plane.
[0033] Fig. 7A-7D is an illustration of the disassembly of the container
into
separate recyclable parts.
[0034] Fig. 8 is a perspective view of an embodiment of a lid.
Detailed Description of the Invention
[0035] The present disclosure provides an eco-friendly container 10 for
liquids, wherein the container components, including the size and shape of the
components, are intended to minimize the material and transportation cost for
both
the materials to make the containers 10 and the final container 10 product.
The
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container 10 is intended for use with non-carbonated beverages. The container
10
disclosed herein uses up to 70% less plastic and non-recyclable materials than
other
environmentally friendly liquid containers. The container 10 also typically
does not
include permanent bonding or adhesives and, therefore, can be easily separated
after the container is used in order to simplify the recycling process. As
such, the
container 10 may use the standard waste collection structures and can fully
utilize
existing recycling systems. Further, the examples provided herein comply with
all
applicable food related regulations.
[0036] In an
embodiment, the container 10 includes a housing 12 including a
side wall 14, a housing first end 16, and a housing second end 18, as shown in
Fig. 1.
The housing 12 may be made of any suitable material, though the advantages
provided herein are best accomplished using a recyclable and biodegradable
product. For example, the housing 12 may be made of a foldable cardboard,
sugarcane pulp, corn pulp, combinations thereof, or any other paper product.
Alternatively, the housing 12 may be made from thin plastic, aluminum, etc.
[0037] The housing
12 may be formed by folding the housing material from a
flat configuration into a three-dimensional shape. For example, the housing 12
may
be formed by folding a single sheet of paper into a cylindrical shape or any
of
various cross-sectional shapes. For example, the housing 12 may be a circular,
triangular, rectangular, hexagonal, octagonal or other cylinder. The three-
dimensional housing 12 may be stabilized using a minimal amount of adhesive
or, in
certain circumstances, without adhesive. For example, the housing 12 may not
require adhesive when the opposing forces of the filled flexible storage bag
20 and
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the shrink-wrap film 24 secure at least two ends of the housing 12 together,
forming
a three-dimensional shape. Alternatively, two ends of the housing material may
include an adhesive, such that when the housing material is folded to connect
two
ends to form the three-dimensional structure, the adhesive maintains the
connection between the two ends to assist in stabilizing the three-dimensional
structure.
[0038] The cross-sectional shape of the housing 12 may be unvaried
throughout the height of the housing 12. In other words, the cross-sectional
area
and shape of the housing first end 16 may be the same as that of the housing
second
end 18. Alternatively, the housing 12 may be tapered such that the cross-
sectional
area of the housing first end 16 may be larger or smaller than the cross-
sectional
area of the housing second end 18 (i.e., the housing 12 may be conical). In
the
examples shown in the figures, the housing 12 is cylindrical and the cross-
sectional
shape of the housing 12 is an octagon. However, it should be understood that
any
suitable shape may form the cross-sectional area of the housing 12, including,
but
not limited to, a triangle, square, rectangle, diamond, pentagon, hexagon,
heptagon,
and circle, among others.
[0039] As mentioned above, the container 10 also enclose a flexible storage
bag 20 within the housing 12, as shown in Fig. 2A. The flexible storage bag 20
may
be made of any suitable material including, but not limited to, plastics or
other
polymeric materials, including various polymer blends, or combinations
thereof.
The flexible storage bag 20 may have a thickness and durability that allows
the
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flexible storage bag 20 to store liquids without leaking, yet allows a straw
to
puncture the flexible storage bag 20.
[0040] As just mentioned, the container 10 may include a liquid stored
within
the flexible storage bag 20, wherein the amount of liquid may be equal or less
than
the storage capacity of the flexible storage bag 20. Typically, the amount of
liquid
occupies less than, and including, 95% of the total volume of the flexible
storage
bag 20. Alternatively, the amount of liquid may occupy less than, and
including,
90%, less than and including 85%, or less than and including 80% of the total
volume of the flexible storage bag 20. The flexible storage bag 20 may be any
suitable size. For example, the flexible storage bag 20 may be capable of
holding
8 ounces (oz.), 12 oz., 16 oz., 20 oz., or 24 oz., among other amounts.
Similarly, the
housing 12 may be various sizes and shapes. Further, it should be understood
that
the term "liquid" is meant to encompass various substances with varying
viscosities,
typically viscosities that may pass through a straw 30. For example, in this
disclosure the term "liquid" includes, but is not limited to, water, non-
carbonated
drinks, sport drinks, energy drinks, smoothies, baby food, pureed food, soups,
milk,
milk shakes, coffee drinks, tea, juice, salad dressing, gravy, broth, and
condiments,
such as ketchup, mustard, mayonnaise, among others.
[0041] The container 10 also includes a lid 22 positioned over the housing
first end 16, wherein at least a portion of the flexible storage bag 20 is
held between
the lid 22 and the housing first end 16, as shown in Fig. 2B. In an example,
at least
two portions of the flexible storage bag 20 are secured between the lid 22 and
the
housing first end 16. The lid 22 may be made of any suitable material.
Typically, the
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lid 22 is made of a thin, plastic material. However, the lid 22 may be made of
aluminum, a polymeric material, various blends of polymeric materials, among
others. Further, the lid 22 may be made of sugar cane pulp, corn pulp, paper
pulp,
among others, and combinations thereof. The shape of the lid 22 may be any
suitable shape that allows the lid 22 to removably attach to the housing first
end 16.
In the example shown in Fig. 2B, the lid 22 is the same shape as the cross-
sectional
shape of the housing 12. Further, the lid 22 may include an opening 28
providing
access to the flexible storage bag 20. As shown in Fig. 2B, the opening 28 may
be
circular.
[0042] The particular design of the lid 22 shown in Fig. 8 allows a very
thin
plastic to be used to form a strong and rigid lid 22. The lid 22 maintains the
structural integrity of the container 10 by preventing the side walls 14 of
the
housing 12 from collapsing. The lid 22 may include an outer edging 34 and an
inner
edging 36. The outer edging 34 is typically flared outward slightly to allow
the lid 22
to easily connect to the housing 12. The inner edging 36 may be flared as
well. In
addition, in some embodiments, the inner edging 36 may be scalloped-shaped
(e.g.,
include a series of indentions 38) to both improve the grip of the lid 22 onto
the
housing 12, as well as to act as a spring to absorb any movement of the side
walls 14
that may otherwise cause a dislodging of the lid 22 from the housing 12.
[0043] The opening 28 in the lid 22 may include a circular wall 40 that
aids a
user in puncturing the surface of the flexible storage bag 20 with a straw 30,
without
the straw 30 slipping on the flexible storage bag 20. Primarily, the circular
wall 40
extends into the body of the housing 12 and makes contact along the top
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the flexible storage bag 20. In doing so, the material at the top of the
flexible storage
bag 20 is held taught such that it is even easier to puncture with the straw
30. In
addition, the circular wall 40 guides the straw 30, visually and physically,
when the
user is attempting to puncture the flexible storage bag 20.
[0044] In addition, the container 10 includes a shrink-wrap film 24
surrounding at least a portion of the housing 12 and at least a portion of the
lid 22,
wherein the shrink-wrap film 24 secures the lid 22 to the housing 12. The
shrink-
wrap film 24 essentially secures the lid 22 and flexible storage bag 20 to the
housing
12 without the use of adhesives or other connecting mechanism, such as tape,
glue,
clips, or fasteners, among others. Because the container 10 does not use
adhesives
to secure various elements together, the container may be easily sorted into
established recyclable products after the container is used. For example, once
the
shrink-wrap film 24 is removed, the lid 22, the flexible storage bag 20, and
the
housing 12 become unattached, thereby allowing the various elements to be
easily
sorted for recycling. For example, the shrink-wrap film 24, lid 22, and
flexible
storage bag 20 may be recycled in a plastic receptacle, whereas the housing 12
may
be recycled in a paper receptacle, with minimal effort required to separate
the
various elements.
[0045] In addition, the shrink-wrap film 24 protects the housing 12 from
moisture. This is particularly important when the housing 12 is made from a
paper
product that is susceptible to damage and/or weakness when exposed to
moisture.
[0046] As shown in Fig. 4, the container 10 may further include at least
one
tab 26 extending from the housing second end 18. Typically, the tab 26 is
foldably
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connected to the housing second end 18. When folded into form for assembly,
the at
least one tab 26 defines a bottom plane perpendicular to the side wall 14. The
tab 26
may be made of the same or different material as the housing 12. Further, the
shape
of the tab 26 may be any suitable shape. For example, the tab 26 may be formed
by
overlapping at least two tabs 26.
[0047] As shown in Fig. 5, the container may include a bottom panel 32 that
may be inserted from the housing first end 16 to the housing second end 18.
The
bottom panel 32 may be made as the same or different material as the housing
12.
In one example, the bottom panel 32 is made of corrugated cardboard in order
help
provide structural integrity to the housing 12 side walls 14 from the inside
of the
container 10.
[0048] For example, the bottom panel 32 may be made from a relatively thick
(e.g., Smm) corrugated cardboard, which adds rigidity to the base assembled
container 10. Without a strengthened bottom panel 32, the container 10 may be
unable to hold up to rigorous use required in distribution, stocking, sale,
and end
use. A strengthened bottom panel 32 can increase the pressure resistance of
the
container 10 by adequately supporting the side walls 14 from the inside of the
housing 12.
[0049] As shown in Fig. 6, the bottom panel 32 may be located along or
adjacent to the bottom plane perpendicular to the side wall 14 that is defined
by the
at least one tab 26. In assembled form, the at least one tab 26 may stabilize
the
bottom panel 32 within the housing 12. Further, the shrink-wrap film 24 may
surround at least a portion of the at least one tab 26, wherein the
combination of the
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tab 26 and the shrink-wrap film 24 cooperate to retain the bottom panel 32
within
the housing 12 along the bottom plane. In other words, the shrink-wrap film 24
and
at least one tab 26 secures the bottom panel 32 such that minimal or no
adhesive is
required for the structural integrity of the container 10. Again, the lack of
adhesive
or other fasteners between the housing 12 and the lid 22 and between the
bottom
panel 32 and tab 26 results in an environmentally friendly container 10, the
components of which are easily separable for recycling purposes. In addition,
the
bottom panel 32 does not require the use of expensive folding equipment as
most
conventional boxes and containers require.
[0050] As
described, the interaction between the bottom panel 32, the tab 26
(or tabs 26), and the shrink-wrap film 24 creates a stable container 10 using
multiple parts without the use of adhesives; the bottom panel 32 providing the
structural support for the side walls 14 and the shrink-wrap film 24
cooperating
with the tab 26 (or tabs 26) to locate and retain the bottom panel 32 in
place. It is
contemplated that this unique structure may form the basis of many variations
of
containers, whether or not paired with the other elements of the container 10
described herein. For example, it is contemplated that in some embodiments of
the
container 10 presented herein, the structural integrity of the container 10
does not
rely on the shrink-wrap film 24, but rather is fully provided by the
configuration of
the housing 12, the bottom panel 32, one or more tabs 26, and the lid 22
alone,
without a shrink-wrap film 24. In another example, an embodiment of the
container
may include a housing 12, with a bottom panel 32 held on place by one or more
tabs 26 without a shrink-wrap film 24. Such embodiments may be aided in
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maintaining their structure by the contents of the container 10, which may
help
secure a stable fit between the housing 12 and the bottom panel 32.
[0051] The container 10 may also include a straw 30 releasably connected to
an outer surface of the shrink-wrap film 24, wherein the straw 30 is
configured to
puncture through the shrink-wrap film 24, proceed through the opening 28 in
the
lid 22, and puncture the flexible storage bag 20. The straw 30 may be encased
in a
thin film that may be removed from the shrink-wrap film 24. The length of the
straw
30 may be expandable in order to access the entirety of the flexible storage
bag 20
once the straw 30 has been inserted.
[0052] The present disclosure also provides a method of forming a
container 10, wherein the method comprises forming a housing 12 including a
side
wall 14, a housing first end 16, and a housing second end 18. The housing 12
may be
formed by folding, either by hand or part of an automated assembly line
process, a
single sheet of material, such as paper, into a three-dimensional structure.
[0053] The method further includes inserting a flexible storage bag 20 into
the housing 12. The flexible storage bag 20 may store a liquid. Alternatively,
the
flexible storage bag 20 may be inserted into the housing 12 empty and
subsequently
filled with a liquid and sealed.
[0054] The method also includes placing a lid 22 over the housing first
end 16, wherein the lid 22 secures at least a portion of the flexible storage
bag 20
between the housing first end 16 and the lid 22. In addition, the lid 22 is
secured to
the housing 12 by heat-sealing a shrink-wrap film 24 around at least a portion
of the
housing 12 and at least a portion of the lid 22.
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[0055] The method may further include releasably attaching a straw 30 to an
outer surface of the heat sealed shrink-wrap film 24, wherein the straw 30 is
configured to puncture through the shrink-wrap film 24 and the flexible
storage
bag 20.
[0056] As illustrated by Figs. 7A-7D, the container 10 disclosed herein is
easily disassembled into separate elements for recycling. As shown in Fig. 7A,
the
shrink-wrap film 24 may be separated from the housing 12. Fig. 7B illustrates
that
the straw 30, the lid 22, and the flexible storage bag 20 are easily separated
from the
housing 12. Figs. 7C-7D illustrate the separation of the straw 30, the lid 22,
and the
flexible storage bag 20 from the housing 12, for recyclable purposes. Because
the
container 10 does not use adhesive or other permanent fastening mechanisms
between the shrink-wrap film 24, the housing 12, the lid 22, and the flexible
storage
bag 20, the components are easily separated into recyclable elements without
complication or substantial effort.
[0057] It should be noted that various changes and modifications to the
embodiments described herein will be apparent to those skilled in the art.
Such
changes and modifications may be made without departing from the spirit and
scope of the present invention and without diminishing its attendant
advantages.
For example, various embodiments of the method and portable electronic device
may be provided based on various combinations of the features and functions
from
the subject matter provided herein.
