U.S. patent application number 09/960709 was filed with the patent office on 2002-05-02 for container for carbonated beverages.
Invention is credited to Cauwood, Peter David, Clark, Victoria Ann, Collingwood, Clennell Douglas, Freeman, Richard Ford, Priest, Mark.
Application Number | 20020050512 09/960709 |
Document ID | / |
Family ID | 26313693 |
Filed Date | 2002-05-02 |
United States Patent
Application |
20020050512 |
Kind Code |
A1 |
Freeman, Richard Ford ; et
al. |
May 2, 2002 |
Container for carbonated beverages
Abstract
A container is provided for carbonated beverages such as beer,
sparkling wines and soft drinks. The container can be made entirely
of plant-based material such as card. In other forms of the
invention additional layers of, for example, plastic or non-woven
material may be provided. The container is therefore easy to
dispose of.
Inventors: |
Freeman, Richard Ford;
(Essex, GB) ; Cauwood, Peter David; (London,
GB) ; Collingwood, Clennell Douglas; (Cambridge,
GB) ; Clark, Victoria Ann; (Tyne ?amp; Wear, GB)
; Priest, Mark; (Cambridge, GB) |
Correspondence
Address: |
BAKER & BOTTS
30 ROCKEFELLER PLAZA
NEW YORK
NY
10112
|
Family ID: |
26313693 |
Appl. No.: |
09/960709 |
Filed: |
June 5, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09960709 |
Jun 5, 2001 |
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09700457 |
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09700457 |
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PCT/GB99/01568 |
May 17, 1999 |
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Current U.S.
Class: |
229/4.5 ;
229/198.2 |
Current CPC
Class: |
B65D 3/22 20130101 |
Class at
Publication: |
229/4.5 ;
229/198.2 |
International
Class: |
B65D 003/22; B65D
005/56 |
Foreign Application Data
Date |
Code |
Application Number |
May 15, 1998 |
GB |
9810537.2 |
Aug 4, 1998 |
GB |
9816945.1 |
Claims
1. A container for a carbonated beverage comprising an external
layer of plant fibre-based material and an internal layer of a
substantially gas impervious material.
2. A container for a carbonated beverage according to claim 1 in
which the external layer comprises multiple plies of the plant
fibre-based material.
3. A container for a carbonated beverage according to claim 1 or 2
wherein four plies of the plant fibre-based material are
provided.
4. A container for a carbonated beverage according to any of claims
1 to 3 wherein the external layer of plant fibre-based material
comprises a sidewall which is a closed curve.
5. A container for a carbonated beverage according to any of claims
2 to 4 wherein two plies of plant fibre-based material are adhered
to each other.
6. A container for a carbonated beverage according to claim 5
wherein the external layer further includes endcaps occluding the
sidewall.
7. A container for a carbonated beverage according to claims 1 to 6
wherein the gas impervious material comprises a membrane of a
plastic material.
8. A container for a carbonated beverage according to claim 6 or 7
in which the sidewall comprises concentric plies of plant
fibre-based material.
9. A container for carbonated beverages according to claim 8 in
which the concentric plies of material are formed into closed
curves by butt jointing.
10. A container for a carbonated beverage according to claim 9
wherein the butt joints of the plies of material are offset from
each other.
11. A container for a carbonated beverage according to claims 4 to
10 wherein the endcaps are conical in shape.
12. A container for a carbonated beverage according to claim 11 in
which the endcaps are adhered to the internal wall of the
sidewall.
13. A container for a carbonated beverage according to claim 11 in
which one endcap is adhered to the interior of the sidewall and the
other endcap is adhered to the exterior of the sidewall.
14. A container of carbonated beverage comprising a container for
carbonated beverage according to any of claims 1 to 13 with
carbonated beverage contained therewithin.
15. A container for a carbonated beverage comprising a sidewall and
at least one endwall at least a portion of which is releasably
attached to the container, wherein the sidewall comprises at least
one layer of cellulose material.
16. A method of manufacturing a container for a carbonated beverage
comprising providing an external layer of plant fibre-based
material and a layer of substantially gas impervious material, the
layer of substantially gas impervious material being placed inside
the external layer of plant fibre-based material.
Description
[0001] This invention relates to a liquid container and in
particular a container for carbonated beverages such as beer,
sparkling wines and soft drinks such as colas and tonic.
[0002] It is known to provide containers for carbonated beverages
such as aluminium or steel cans and bottles manufactured from glass
or a plastic material such as PET. The beverages contain a
dissolved gas such as CO.sub.2. The CO.sub.2 may be present in the
beverages as a result of the manufacturing process such as brewing
in the case of beer or may be dissolved into the liquid such as
usually the case with soft drinks. Containers for such beverages
must be capable of physically withstanding the pressure of the gas,
that is, they must not rupture or creep under pressure and they
must also contain the gas without allowing it to escape from the
container. An acceptable shelf life for a beverage so contained is
approximately three months. Current containers such as glass or
plastic bottles and cans do provide the necessary shelf life
however there are drawbacks with such existing containers.
[0003] Cans, and in particular aluminium cans, can be recycled
however such recycling requires a relatively large input of energy
and further requires that the containers be sorted and transported
to a recycling plant. Cans, even recent aluminium cans, still
require the use of several grams of metal. Another drawback of cans
is that the outer surface thereof is difficult to provide printing
on. Various screenprinting techniques exist, however these are
somewhat limited and in many cases the graphics capable of
representation on the outer wall of an aluminium can are limited to
simple designs of primary colours.
[0004] In the case of bottles whether of a plastics material or
glass printing directly onto the outer surface of such a container
is not normally possible. A further layer must be provided in order
to enable the graphics to be printed. This complicates the
manufacturing process and requires a separate layer of material
which may be dissimilar to the material of the main body of the
container thus complicating recycling.
[0005] The present invention provides a container for carbonated
beverages. These beverages may comprise beer, fizzy wine or other
drinks such as soft drinks. Existing containers do provide for
adequate material strength and provide a gas barrier so that any
dissolved gas does not pass out of the container. Existing
techniques such as providing a glass or PET material bottle do
adequately contain such beverages however they do have limitations
in that in order to recycle them a collection facility must be
provided and such containers are relatively bulky and somewhat
heavy. There is a further drawback in using PET in that recycled
PET cannot be placed in contact with food so when constructing a
container from recycled PET a layer of virgin PET must be provided
on the internal surface which will contact the beverage with the
regrind or recycled PET providing the outer layer. Card made from
plant or vegetable-based material such as using the fibres of flax,
wood or hemp is readily recyclable or disposable. For example it
can be composted, burnt or recycled in a standard paper or card
recycling plant. Card may also be readily printed with detailed
graphics. Card has a further advantage in that it is substantially
opaque and beverages such as beer have been found to keep better
when kept out of contact with light. As can be seen from the
figures preferred forms of the present invention as shown in FIG. 1
provide a full opening container, that is, when the endcap is
removed full access to the container is provided. This provides a
container of beverage which is easier to drink from as opposed to
current aluminium or steel cans in which a smaller, that is, less
than full aperture opening is provided.
[0006] Card such as card produced from vegetable matter, for
example, wood pulp, hemp or flax material does provide a matt
surface which can be readily printed upon. However a single ply of
card does not provide a sufficient degree of dimensional stability,
that is, it creeps under pressure. Further, card does not provide
for a sufficient gas barrier to contain gas present within a
container manufactured therefrom. Current card containers such as
the "Tetrapak Tetrabrick" can be used to contain beverages which
are non-carbonated. However due to the current technique of
manufacturing the joints of the container are not mechanically
strong enough to withstand any degree of internal pressure. The
shape of the container is also not suitable for carbonated beverage
containment.
[0007] The current invention attempts to overcome the problems of
the above-mentioned known devices by providing a container
primarily of a vegetable matter card or paper which provides
sufficient dimensional stability and gas impermeability to enable
it to be used to contain carbonated beverages.
[0008] Exemplary embodiments of the present invention will now be
described with reference to the accompanying drawings.
[0009] FIG. 1 shows a vertical cross-section through a preferred
form of the present invention. The beverage container 1 provides an
outer wall 2 of a card material such as card produced from
vegetable matter and further includes an internal membrane 3. The
internal membrane 3 is preferably of a plastic material such as
nylon, polyethylene or PET. In the preferred form of the invention
as shown in FIG. 1 a conical end cap 4 is provided over the top of
the container. There may also be present a further cap 5 which is
flat-ended.
[0010] FIG. 2 shows a container according to the present invention
without the internal membrane. This figure shows a vertical
cross-section and illustrates the structure of the outer wall of
the container including the bottom endcap 6.
[0011] FIG. 3 illustrates the construction of the side wall of the
beverage container and shows a preferred laminated structure. In
this form of the invention there are present four layers 10, 11, 12
and 13. These layers are produced from pieces of card which are
arranged concentrically. The joints of the card 20, 21, 22 and 23
are most preferably butt joints, that is, the card is curved and
joined end-to-end. In the preferred form of the invention which
utilises four layers the joints 20, 21, 22 and 23 are offset from
each other by 90.degree.. This ensures that in this form of the
invention there are three unbroken layers of card either above or
below each joint.
[0012] FIG. 4 shows the construction of an endcap according to a
preferred form of the invention. This endcap is constructed from a
series of nested cones. These cones 30, 31, 32 and 33 preferably
are produced from a circular piece of card which has a sector
removed. It has been found that a cone angle of approximately
120.degree. provides for adequate strength. A series of extensions
or tabs 40 are preferably provided on the uppermost cone in order
to facilitate fixing of the endcap to the sidewall.
[0013] FIG. 5 shows a horizontal cross-section showing the expanded
layers in a preferred form of the invention. These layers include
butt joints which are offset from each other by 90.degree..
[0014] FIG. 6 shows another form of the present invention in which
three layers of card are-provided. The butt joints of this form are
offset from each other by 120.degree..
[0015] FIG. 7 shows another form of endcap. In this form the endcap
is hemispherical and is provided with a sidewall 42 which enables
fixment to the main sidewall of the beverage container.
[0016] FIG. 8 shows another form of conical endcap, this form being
produced from triangular segments.
[0017] FIG. 9 shows a perspective view of another technique of
closing the container, in this case the top of the container, by
means of folding over the sidewall to provide a folded or crimped
region 50. In this form of the invention the sidewall is flattened
and then folded over at least once and preferably two or more
times. The crimped region 50 may be glued or heat sealed.
[0018] FIGS. 10 and 11 further illustrate the form of the invention
which utilises a crimped region, FIG. 10 showing in perspective and
partial cross-section a single fold and FIG. 11 showing in
perspective and partial cross-section a double fold.
[0019] FIG. 12 shows a form of the sidewall of the present
invention. This sidewall is approximately cylindrical and thus
provides for ease of manufacture in that the various layers or
plies of the sidewall are substantially rectangular in shape.
[0020] FIG. 13 shows a perspective view of another form of
sidewall. In this case the shape is substantially frustoconical
having a larger upper opening and smaller lower opening. This form
of the present invention is still relatively easy to manufacture
and provides a further advantage in that it approximates the shape
of a traditional glass.
[0021] FIG. 14 shows another form of the present invention being a
frustoconical shape having a smaller upper opening and larger lower
opening.
[0022] FIGS. 15 to 19 show various possible shapes for the sidewall
of a container according to the present invention.
[0023] FIG. 15 shows a horizontal cross-section through a preferred
form of the invention in which the cross-section is circular.
[0024] FIG. 16 shows another shape which is possible f or a
sidewall when viewed in cross-section, this shape being a tround. A
tround shape has the advantage of providing for ease of indexing,
that is, a series of containers of such a shape can be conveyed
along a path or through an opening with ease.
[0025] FIG. 17 shows another and less preferred form of the present
invention in which a polygon, in this case a pentagon, is
constructed from a series of separate sidewall pieces 60, 61, 62,
63 and 64.
[0026] FIG. 18 shows a polygon shape, again a pentagon, in which
the sidewall is constructed from a single piece of material. Such a
construction would involve a number of plies of material similar to
the construction of the circular cross-section sidewall described
earlier.
[0027] FIG. 19 shows another possible cross-section, in this case
an octagon having unequal side lengths.
[0028] FIG. 20 shows another less preferred technique of
constructing the sidewall of a beverage container, in this case the
material is arranged in a spiral or convolute. That is, a single
piece of material is provided which is wound into an approximately
circular shape.
[0029] FIG. 21 shows the preferred form of the invention utilising
concentric plies of material.
[0030] FIG. 22 shows yet another form of the invention in which the
sidewall is constructed from a helically wound piece of material
70. Such a technique is known for the construction of inner cores
of, for example, toilet paper. In this form of the present
invention a number of plies of material, for example four, are
provided, the joints of each ply being butt-jointed to each other
and the joints of each separate ply being offset from each other by
approximately equal angles.
[0031] FIGS. 23, 24, 25 and 26 show in cross-section various forms
of jointing in providing the sidewall of the present invention.
[0032] FIG. 23 shows the preferred form in which a butt joint is
provided and the material plies are adhered to each other by a
suitable adhesive, for example, polyvinyl acetate (PVA) glue or
another food-approved adhesive.
[0033] FIG. 24 shows another preferred technique in which the
joints are skived, that is, the joint is similar to the butt joint
however the pieces of material to be jointed to each other are
angled. This technique has the advantage of providing a greater
surface area for the ply to adhere to itself.
[0034] FIG. 25 shows another possible form of joint in which the
ply is overlapped.
[0035] FIG. 26 shows a preferred jointing technique in which,
similar to that illustrated in FIG. 25, an overlap joint is
provided however this is further sealed by a separate layer, for
example tape 80.
[0036] FIG. 27 shows a construction technique of a sidewall
according to the present invention. This involves the layering of a
ply onto a former 100. As illustrated in FIG. 27 the former 100 may
comprise a cylinder and the various plies making up the sidewall
are simply layered onto the cylinder as it rotates. The offset of
the joints between the plies or layers is achieved by starting the
separate plies at points offset from the underlying joint.
[0037] FIG. 28 shows a similar technique used to provide a
container which is tround in cross-section. In this case the former
101 is of course of a tround shape. Other formers may be used to
provide various sidewalls of differing shapes.
[0038] The present invention provides a container for a carbonated
beverage 1 which utilises multiple layers of differing materials.
One of those layers 2 comprises one and preferably multiple plies
of a plant fibre-based material. Such a plant fibre-based material
may comprise card produced from wood fibres according to any of the
well-known card or paper-making techniques. It has been found that
multiple layers of wood fibre card of approximately 90 grams per
square metre in weight can provide sufficient strength to contain a
carbonated beverage when such material is layered or laminated.
Other suitable plant fibre-based materials such as hemp or flax
fibre-based cards may also be utilised. The outer surface of the
sidewall 2 provides an area onto which graphics may be printed. The
use of material of a plant fibre-based nature enables a number of
the known techniques for printing onto plant fibre-based materials
to be utilised.
[0039] Most plant fibre-based materials are not moisture-proof to
any great degree and therefore the outer surface of the sidewall 2
of the container for carbonated beverages may be coated with a
waterproofing material such as a plastic material or a wax. Such a
layer provides a degree of protection for the sidewall and may
therefore allow for longer shelf-life.
[0040] The membrane barrier material 3 which is the internal layer
of the container for a carbonated beverage may be produced from a
number of suitable materials. It may comprise a laminated or
multilayer material. Suitable materials have been found to include
nylon or polypropylene or polyethylene or polyethylene napthalate.
Such materials may further include, for added protection, a thin
layer of metal such as aluminium. Devices according to at least
preferred forms of the present invention have been found to be
capable of containing pressures of up to 40-75 pounds per square
inch. The containment of such pressures was stable over the
intended shelf-life of typical carbonated beverages, that is, over
three months. In preferred forms of the invention, for example as
illustrated in FIG. 1, the internal pressure of the carbonated
beverage has the effect of tightening the bond of the upper
endpiece 4 to the sidewall 2. This is also the case in forms of the
invention where the outer edges of the topmost piece 4 are rolled
together with the upper portions of the sidewall 2 or the folded
skirt portion 13 of the sidewall 2. In such situations it may be
beneficial to provide means for releasing the pressure contained
prior to opening. For example a weakened portion may be provided on
the endcap 4, the user removing the weakened portion by, for
example, pushing or pulling off the weakened portion thereby
releasing the pressure and therefore decreasing the bonding of the
upper endcap 4 to the sidewalls 2 thus facilitating opening. In
forms of the invention such a weakening may comprise the middle or
upper portion of the conical endcap 4 which may be either scored,
that is, perforated in such a way as to enable a central portion
thereof to be removed or may comprise a separate conical subportion
which can be removed.
[0041] In preferred forms of the invention the gas barrier material
3 need not provide any great degree of pressure containment of the
carbonated beverage. It therefore may be relatively thin as long as
it provides the necessary degree of gas impermeability. It has been
found that a container for carbonated beverage constructed
according to a preferred form of the invention provides a container
in which the membrane 3 provides approximately 2-5% of the total
mass of the container. This is an advantage in that the barrier
material 3 is likely to be more expensive and in most cases much
more expensive than the material of the outer wall 2.
[0042] The degree of attachment of the barrier material 3 to the
sidewall 2 need not be great. To some degree the internal pressure
of the carbonated beverage within the membrane 3 will push it
against the sidewall 2. In preferred forms of the invention the
membrane material 3 may be easily removed from the sidewall after
disposal of the container. This enables the barrier material 3 to
be separately processed or recycled whereas the sidewall 2 may be
subject to different disposal options. For example the barrier
material 3 may be floated off recycled and the outer wall or layer
2 may be otherwise disposed of for example being a plant
fibre-based material it may be used in landfill, burnt or
composted.
[0043] As shown in the preferred form of the invention as
illustrated in FIG. 1 the removal of the endcap 4 of the container
for carbonated beverage provides a full aperture opening. That is
the top of the container is fully open and the beverage contained
therewithin can be readily consumed. However in other less
preferred forms of the invention the endcap may be provided with
points of weakening or for example a tear-tab which the user can
remove in order to obtain access to the beverage contained therein
through an aperture which does not occupy the full end of the
container.
[0044] The preferred form of the invention as shown in FIG. 1 may
be further provided with an additional overcap 5. Such an overcap
may be simply a cylinder closed at one end which fits over the
conical endcap 4. This additional overcap further protects the
endcap 4. This is particularly important if the endcap 4 has as
described previously a point of weakening or tear-tab to enable
non-full aperture access to the beverage to be obtained. An
additional use of the additional endcap 4 is to enable promotional
material such as instant win tickets to be placed under the outer
endcap 5. Until purchased such promotional material would not be
visible, however once purchased a user would be able to remove the
outer endcap 5 and view the promotional material.
[0045] The present invention provides containers for carbonated
beverages which may prove attractive to beverage producers for a
number of reasons as described above. Additionally such a container
for carbonated beverage is less likely to cause injury if thrown at
persons. This may prove an advantage.
[0046] The endcap 4 may be secured to the sidewall 2 by a number of
means. In the preferred forms of the invention as illustrated the
conical endcap 4 includes a skirt portion comprising a
substantially cylindrical band of material extending from the outer
surface of the cone. This may prove to be a preferred alternative
to the form of the endcap as shown in FIG. 4 which includes a
number of tabs 40. It is believed that the endcap of a conical
nature as shown in FIG. 4 will be preferred when used as a lower
occlusion as shown in FIG. 1 and indicated by the reference numeral
9 whereas the form of endcap comprising a cone with an additional
skirt or cylindrical wall will be preferred when used as a top
endcap as shown in FIG. 1. In forms of the invention the sidewall 2
may be rolled or folded outwardly to provide an upper lip 13 to the
sidewall 2. The upper endcap 4 may additionally be provided with a
folded or rolled internal lip 14. The metallised layer, for example
the layer of aluminium, is extremely thin, up to approximately 6
microns and maybe less in thickness. The metal layer may be coated
with a plastic or other polymer material. Various techniques exist
in the art to which this invention relates to enable such a thin
layer of metal to be bonded with a membrane such as a plastic
membrane.
[0047] Such metallised layers are flexible, provide a degree of
thermal insulation and may also enhance the gas impermeability of
the membrane. As shown in FIG. 1 the lips 13 and 14 may be sized so
as to secure the endcap 4 to the sidewall 2. In other forms of the
invention the skirt of the endcap 4 may be provided with points of
weakening or a tear strip to enable the user to readily remove the
endcap from the beverage container. In other forms of the invention
the endcap 4 may be secured to the sidewalls 2 by means of
serrations which are provided inside the skirt of the endcap 4 and
on the outside of the sidewall 2. Such serrations may be of a
plastic material and provide for the endcap to click or clip onto
the sidewall. Other forms of the invention may provide an endcap 4
which can be screwed or twisted off the sidewall 2. The lower
endcap 9 may in less preferred forms of the invention be of a
similar form to that as described in relation to the upper endcap
4. However preferably it is mounted internally in the sidewall 2.
This means that the endcap 9 may be positioned such that the point
of the cone may be no lower than the lower portions of the
sidewall. This can provide a stable base for the beverage
container. The lower endcap 9 may be adhered inside the sidewall 2
by means of the tabs 40. A suitable food-grade or food-approved
adhesive such as PVA may be used.
[0048] FIG. 3 shows various layers of sidewalls. In this form of
the invention the layers 20, 21, 22 and 23 are separate plies of
plant fibre-based material card. As shown in the figures the ends
of the various plies are butted together and joined at their ends.
These joints are preferably glued using a suitable food-grade or
food-approved adhesive such as PVA and the joints are offset from
one another, in this case as four layers are provided the offset is
90.degree.. In forms of the invention wherein three layers are
provided the joints are offset by 120.degree.. The various plies or
layers are laminated to each other using again a suitable
food-grade or food-approved adhesive such as PVA.
[0049] In preferred forms of the invention the layers may comprise
the same material, for example they may all comprise a wood pulp
paper. In other forms of the invention differing plies or layers
may be utilised. For example one layer may comprise recycled plant
fibre-based card whereas other layers may comprise virgin or
non-recycled fibre-based card. In other forms of the invention the
orientation of the fibres may differ in the various layers. For
example alternate layers may comprise plies having fibres arranged
substantially vertically then horizontally. This is believed to
provide a greater structural strength container. This method may
also allow the outermost ply or layer to be of a different
material, for example the outermost layer may comprise a material
which can be readily printed upon. And as mentioned previously the
outermost layer may be water or moisture-proofed using various
techniques which are known to persons skilled in the art to which
the invention relates.
[0050] The multilayer construction of the endcaps is shown in
Figure 4. It is preferred that at least three and preferably four
layers are provided in the endcap. In this case they are shown in
exploded view. The various layers 30, 31, 32 and 33 comprise a set
of nested cones. These cones may be most simply produced from
circular pieces of material which have a sector removed to enable
them to be formed into a cone. It has been found experimentally
that cones having an angle of approximately 120.degree. provide
sufficient strength. Again as discussed in relation to the
sidewalls the materials of the plies of the cones 30, 31, 32 and 33
may differ in order to provide additional material strength or
utilise advantages of certain materials such as ease of
printing.
[0051] Other less preferred endcaps are shown in FIGS. 7, 8 and 9.
FIG. 7 shows a hemispherical endcap. This endcap 42 requires a
different construction technique from the conical endcap. A
different technique of constructing the conical endcap is
illustrated in FIG. 8 wherein the cone is constructed from sectors
of material. The sectors are adhered to one another using a
suitable food-grade adhesive such as PVA.
[0052] FIG. 9 shows an alternative method of sealing one or both
ends of the container for a carbonated beverage. In this case the
end is flattened and folded or crimped over 50. This technique is
used in the manufacture of tubes of such substances as toothpaste
etc. and the sealing may be enhanced by use of adhesive or heat
sealing. A tearaway or ripaway portion may be provided in the
crimped region 50 to enable users to readily obtain access to the
carbonated beverage contained therein.
* * * * *