U.S. patent application number 12/850808 was filed with the patent office on 2011-02-10 for container for bottle-in-box package.
Invention is credited to Joseph Craig Lester, Douglas Bruce Zeik, Kyle Vincent Zink.
Application Number | 20110031243 12/850808 |
Document ID | / |
Family ID | 42797433 |
Filed Date | 2011-02-10 |
United States Patent
Application |
20110031243 |
Kind Code |
A1 |
Lester; Joseph Craig ; et
al. |
February 10, 2011 |
Container for Bottle-In-Box Package
Abstract
Containers useful in bottle-in-box applications among others,
including a blow molded portion and a non-blow molded portion
integrally connected, wherein the blow molded portion includes: (i)
at least one layer of polypropylene thermoplastic material having a
flexural modulus (1% secant) of from about 140,000 psi to about
220,000 psi under ASTM D790; (ii) a containing volume of at least
two liters suitable for containing a liquid or semi-liquid
composition; and (iii) a containing volume to polypropylene
thermoplastic material mass ratio of greater than 100 mL/gram;
wherein the non-blow molded portion further includes an attachment
means for connecting a dispenser.
Inventors: |
Lester; Joseph Craig;
(Liberty, OH) ; Zink; Kyle Vincent; (West Chester,
OH) ; Zeik; Douglas Bruce; (Middletown, OH) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;Global Legal Department - IP
Sycamore Building - 4th Floor, 299 East Sixth Street
CINCINNATI
OH
45202
US
|
Family ID: |
42797433 |
Appl. No.: |
12/850808 |
Filed: |
August 5, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61231532 |
Aug 5, 2009 |
|
|
|
Current U.S.
Class: |
220/23.87 ;
215/44 |
Current CPC
Class: |
B29C 49/10 20130101;
B29C 49/06 20130101; B65D 1/0207 20130101; B29C 49/221 20130101;
B29K 2623/12 20130101; B29C 49/0005 20130101; B29K 2023/12
20130101; B65D 77/065 20130101; B29K 2023/086 20130101 |
Class at
Publication: |
220/23.87 ;
215/44 |
International
Class: |
B65D 21/02 20060101
B65D021/02; B65B 7/28 20060101 B65B007/28 |
Claims
1. A container comprising a blow molded portion and a non-blow
molded portion integrally connected, wherein the blow molded
portion comprises: (i) at least one layer of polypropylene
thermoplastic material having a flexural modulus (1% secant) of
from about 140,000 psi to about 220,000 psi under ASTM D790; (ii) a
containing volume of at least two liters suitable for containing a
liquid or semi-liquid composition; and (iii) a containing volume to
polypropylene thermoplastic material mass ratio of greater than 100
mL/gram; wherein the non-blow molded portion further comprises an
attachment means for connecting a dispenser.
2. A container according to claim 1, wherein the containing volume
to polypropylene thermoplastic material mass ratio is greater than
125 mL/gram.
3. A container according to claim 2, wherein the containing volume
to polypropylene thermoplastic material mass ratio is greater than
150 mL/gram.
4. A container according to claim 1, wherein the containing volume
to polypropylene thermoplastic material mass ratio is from about
100 to about 250 mL/gram.
5. A container according to claim 1, wherein the containing volume
is from about 3 liters to about 20 liters.
6. A container according to claim 4, wherein the containing volume
is from about 5 liters to about 10 liters.
7. A container according to claim 1, wherein the polypropylene
thermoplastic material has a Water Vapor Transmission Rate of from
about 5 gm*25 .mu.m/m.sup.2/day.
8. A container according to claim 1, wherein the container passes
the vibration stability test.
9. A container according to claim 1, wherein the attachment means
is selected from threads.
10. A container according to claim 10, wherein the dispenser
selected from tubes, taps, spouts, valves, pumps, spray nozzles,
moveable diaphragms, and combinations thereof.
11. A container according to claim 10 wherein the dispenser is a
self-venting press-tap.
12. A container according to claim 1, wherein the container is
formed from a polypropylene pre-form and has a hoop blow-up stretch
ratio of from about 4.5 to about 10.
13. A container according to claim 11, wherein the container is at
least partially encompassed by an outer structural container.
14. A container having a height to width ratio of from about 3:1 to
about 1:3, comprising a blow molded portion and a non-blow molded
portion integrally connected, wherein; (a) the blow molded portion
comprises: (i) at least one layer of polypropylene thermoplastic
material having a flexural modulus (1% secant) of from about
140,000 psi to about 220,000 psi under ASTM D790; (ii) a containing
volume of from about 2 liters to about 20 liters, suitable for
containing a liquid or semi-liquid composition; and (iii) a
containing volume to polypropylene thermoplastic material mass
ratio of greater than 75 mL/gram; and (b) the non-blow molded
portion comprises; (i) at least one layer of polypropylene
thermoplastic material having a flexural modulus (1% secant) of
from about 140,000 to about 220,000 psi; and (ii) an attachment
means for connecting a dispenser.
15. A container according to claim 14, wherein the attachment means
is selected from threads.
16. A container according to claim 14, wherein the container is at
least partially encompassed by an outer structural container.
17. A container according to claim 16 wherein the outer structural
container is a corrugated board box.
18. A container according to claim 14 wherein the container is
formed from a polypropylene preform having a hoop blow-up stretch
ratio of from about 4.5 to about 8.
19. A container according to claim 14, wherein the dispenser
selected from tubes, taps, spouts, valves, pumps, spray nozzles,
moveable diaphragms, and combinations thereof.
20. A container according to claim 10 wherein the dispenser is a
self-venting press-tap.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims benefit of U.S. Provisional
Application Ser. No. 61/231,532, filed Aug. 5, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to plastic bottles fortified
by and encompassed within cardboard boxes to form packaging useful
for the storage, shipment and dispensing of liquid or gel products
such as detergents and beverages.
BACKGROUND OF THE INVENTION
[0003] Collapsible containers such as foil pouches and mono- or
multi-layer thermoplastic laminate bags are well known for storing
and dispensing a variety of compositions, particularly liquids and
gels. For example, such containers may be used as liners for
cartons/boxes for beverages, or may be used in bag-in-box
applications. For instance, numerous consumer packaged goods such
as wine and fruit juice are currently available on the market in
bag-in-box containers. Such bag-in-box containers typically include
the thermoplastic laminate bag as a liner and an outer container
(formed of for example, corrugated cardboard) that provides
structure to the liner to allow for storage, shipment and/or
dispensing of the composition contained therein. Such bag-in-box
containers have also enjoyed success in the food-service supply
area, allowing for relatively inexpensive packaging of large
quantities of condiments (such as ketchup), cooking oil,
concentrates (syrups) for fountain soft drinks, and similar food
composition storage.
[0004] However, problems may exist with such thermoplastic laminate
bag collapsible containers. First, some of them are formed from
multiple thermoplastic sheets which are sealed together with either
adhesive or heat-sealing. The seams where the sheets are joined
together could leak and therefore be unsuitable for consumer use,
particularly where there is a desire to protect consumers from the
compositions contained therein. Furthermore, the bags constructed
from multiple layers of thermoplastic materials may be expensive to
construct and it may be difficult to re-close the container once it
is opened.
[0005] More recently, "collapsible" containers blow-molded from
polyethylene terephthalate (PET) soft drink preforms (such as those
used for making soft drink, beer or juice containers) have been
suggested as an alternative to thermoplastic bag containers. For
example, U.S. Pat. No. 6,676,883 to Hutchinson discloses such
pre-forms and their construction into articles. And in U.S. Pat.
No. 7,204,950, traditional bag-in-box applications have been
modified by substituting liners constructed by blow-molding PET
thermoplastic preforms for the traditional thermoplastic bags,
resulting in what may then be referred to as a "PET bottle-in-box"
containers.
[0006] However, it has now been surprisingly discovered that such
PET bottle-in-box containers are unsuitable for storing and
shipping flowable compositions, particularly liquid laundry
detergents. When attempting to reapply such PET bottle-in-box
container teachings to the storage and shipment of liquid laundry
detergents, it was surprisingly found that when the "collapsible"
blow-molded PET preform bottle containers were subjected to
vibrational stress (such as during shipping), creasing in the walls
of the PET container occurs and subjects the container to leakage.
Such leakage is entirely unacceptable both from a consumer
standpoint and for safety considerations.
[0007] One solution to such creasing is to form heavier walls of
PET. However, such walls are less flexible, negating the desired
collapsibility, are more costly (additional materials needed), and
are harmful to the environment by creating additional waste when
the container is eventually disposed.
[0008] Another solution is to add pressurization to the headspace
of the closed container to provide stability. Such an approach is
often used with thin-walled thermoplastic water bottles. However,
this solution creates new manufacturing difficulties for
introducing the gas to the package as well as consumer suitability
problems. Further, when transporting through altitudes, pressure
changes may occur and still allow creasing.
[0009] Therefore, a need still exists for an improved container for
transporting flowable compositions, particularly liquid laundry
detergent products, in collapsible containers having suitable
structural stability.
SUMMARY OF THE INVENTION
[0010] It has now surprisingly been discovered that blow-molded
polypropylene containers can provide desired flexibility for
bottle-in-box applications while maintaining the structural
stability preferable for the transportation and storage of flowable
compositions, all while reducing cost and environmental impact.
[0011] The present invention therefore relates to containers
including a blow molded portion and a non-blow molded portion
integrally connected, wherein the blow molded portion includes: (i)
at least one layer of polypropylene thermoplastic material having a
flexural modulus (1% secant) of from about 140,000 psi to about
220,000 psi under ASTM D790; (ii) a containing volume of at least
two liters suitable for containing a liquid or semi-liquid
composition; and (iii) a containing volume to polypropylene
thermoplastic material mass ratio of greater than 100 mL/gram;
wherein the non-blow molded portion further includes an attachment
means for connecting a dispenser.
[0012] The present invention further relates to containers having a
height to width ratio of from about 3:1 to about 1:3, comprising a
blow molded portion and a non-blow molded portion integrally
connected, wherein the blow molded portion comprises: (i) at least
one layer of polypropylene thermoplastic material having a flexural
modulus (1% secant) of from about 140,000 psi to about 220,000 psi
under ASTM D790; (ii) a containing volume of from about 2 liters to
about 20 liters, suitable for containing a liquid or semi-liquid
composition; and (iii) a containing volume to polypropylene
thermoplastic material mass ratio of greater than 75 mL/gram; and
the non-blow molded portion comprises; (i) at least one layer of
polypropylene thermoplastic material having a flexural modulus (1%
secant) of from about 140,000 to about 220,000 psi; and (ii) an
attachment means for connecting a dispenser.
[0013] The present invention further relates to such containers
wherein the containing volume to polypropylene thermoplastic
material mass ratio is greater than 125 mL/gram, alternatively
greater than 150 mL/gram, still alternatively is from about 100 to
about 250 mL/gram.
[0014] The present invention further relates to such containers
wherein the containing volume is from about 3 liters to about 20
liters, alternatively from about 5 liters to about 10 liters.
[0015] The present invention further relates to such containers
wherein the polypropylene thermoplastic material has a Water Vapor
Transmission Rate of from about 5 gm*25 .mu.m/m.sup.2/day.
[0016] The present invention further relates to such containers
wherein the container passes the vibration stability test.
[0017] The present invention further relates to such containers
wherein the attachment means is selected from threads.
[0018] The present invention further relates to such containers
wherein the dispenser selected from tubes, taps, spouts, valves,
pumps, spray nozzles, moveable diaphragms, and combinations
thereof.
[0019] The present invention further relates to such containers
wherein the dispenser is a self-venting press-tap.
[0020] The present invention further relates to such containers
formed from a polypropylene pre-form and having a hoop blow-up
stretch ratio of from about 4.5 to about 10.
[0021] The present invention further relates to such containers
wherein the container is at least partially encompassed by an outer
structural container.
[0022] The present invention further relates to such containers
wherein the outer structural container is a corrugated board
box.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 illustrates a preform shape useful in the
invention;
[0024] FIG. 2 illustrates the cross-section of the preform of FIG.
1;
[0025] FIG. 3 illustrates a cross-section of a multi-layer preform
shape useful in the invention;
[0026] FIG. 4 illustrates a cross-section of a multi-layer preform
shape useful in the invention in which the outer layer extends to
the non-blow molded finish;
[0027] FIG. 5 illustrates a cross-section of a preform inserted in
a mold useful in the invention;
[0028] FIG. 6 illustrates a container blown from the preform of
FIG. 5 useful in the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] A suitable container useful for the storage, shipment,
and/or dispensing of flowable compositions may be formed from
polypropylene. Containers herein include a blow molded portion and
a non-blow molded portion integrally connected.
Container
[0030] Containers according to the present invention include a blow
molded portion and a non-blow molded portion integrally connected.
In one embodiment, the container has a height to width ratio of
from about 3:1 to about 1:3, alternatively from about 2:1 to about
1:2 and still alternatively from about 1:1 with length measured at
the longest dimension and disregarding the dispenser when
measuring.
[0031] In one embodiment, the container contains within a
composition. When the container contains within a composition, the
container/composition combination may be non-pressurized. As used
herein, "non-pressurized" means that that the containers are not
subjected to gas or other pressurization means that would result in
the increase of pressure inside the container vs. the atmospheric
pressure found outside the container when initially filled. It is
possible that after filling, pressurization may naturally occur
during shipment due to changes in atmospheric pressure and/or
reactions within the formulation.
Blow Molded Portion
[0032] The blow molded portion is integrally connected to a
non-blow molded portion. As used herein, "integrally connected"
means formed from a single preform.
[0033] The blow molded portion has a containing volume of at least
two liters, alternatively from about 3 liters to about 20 liters,
alternatively from about 5 liters to about 10 liters, alternatively
from about 2 liters to about 20 liters. As used herein "containing
volume" means the volume of space contained within the blow molded
portion. The blow molded portion is suitable for containing a
liquid or semi-liquid composition.
[0034] In one embodiment, the wall thickness of the entire blow
molded portion ranges from about 0.0005 to about 0.200, with a mean
blow molded portion wall thickness from about 0.004 to 0.010,
alternatively from about 0.004 to about 0.007 inches when measured
with a Hall Effect Thickness Gauge according to the method found in
the Plastic Bottle Institute Technical Bulletin PBI 21 1984 Section
7.2.
[0035] In one embodiment, the blow molded portion is seamless. As
used herein, "seamless" means substantially free of lines formed by
abutting edges of polymeric material. Seamless blow molded portions
are typically formed by extrusion or injection stretch blow-molding
as opposed to bag structures which have adhesive or heat-sealed
seams as well as other seams needed to include any non-blow molded
finish. The transition from the blow molded portion to the non-blow
molded portion is not a "seam" for purposes of the seamless blow
molded portions described herein.
[0036] Polypropylene Thermoplastic Material
[0037] The blow molded portion includes at least one layer of
polypropylene thermoplastic material. The blow-molded portion may
include more than one layer of polypropylene thermoplastic material
or may include a layer of polypropylene thermoplastic material in
combination with one or more layer(s) of another thermoplastic
material and/or a coating. The polypropylene thermoplastic material
may be selected from polypropylene homopolymers, polypropylene
copolymers, and/or blends thereof. In one embodiment, the
polypropylene thermoplastic material is a polypropylene copolymer.
Polypropylene thermoplastic materials are commercially available
from suppliers such as Chevron-Phillips and Lyondell-Basell. One
example of a commercially available material is the Marlex grade
material available from Chevron-Phillips. Pre- or Post-consumer
recycled materials can be used.
[0038] Other thermoplastic materials that may be used in addition
to the polypropylene include ethylene vinyl alcohol co-polymer
(EVOH) and post-consumer recycled materials that may include a
combination of thermoplastic materials. Coatings may also be used
such as antistatic or UV blocking coatings.
[0039] Polypropylene thermoplastic materials useful herein have a
flexural modulus (1% secant) of from about 140,000 psi to about
220,000 psi under ASTM D790. Furthermore, in one embodiment, the
polypropylene thermoplastic material has a Water Vapor Transmission
Rate of from about 5 gm*25 .mu.m/m.sup.2/day or less than about 5%
per year, alternatively less than 2% per year, alternatively less
than 1% per year, when measured at 37.8.degree. C. and 90% relative
humidity, per ASTM F1249. The flexural modulus and Water Vapor
Transmission Rate values are provided based upon the material
itself, as tested in a "dog bone" form, and not necessarily as if
tested in a final container form.
[0040] The blow molded portion has a ratio of containing volume to
polypropylene thermoplastic material mass of greater than 100
mL/gram, alternatively having a volume to mass ratio of greater
than 125 mL/gram, alternatively greater than 150 mL/gram. In one
embodiment, the volume to mass ratio is from about 75 mL/gram to
about 250 mL/gram.
Non-Blow Molded Portion
[0041] The containers herein have a non-blow molded portion
integrally connected with the blow molded portion. As used herein,
"non-blow molded finish" refers to a portion of the container
shaped preferably for attachment (removably or fixed).
[0042] The non-blow molded portion includes an attachment means for
connecting a dispenser, cap, or dispensing or filling apparatus.
Attachment means may include clips, threads a bayonet mount, a
compression fitting or any other known attachment means.
[0043] As used herein a "dispenser" refers to any means for
allowing a flowable composition held within the containers herein
to evacuate the container. Dispensers may therefore include tubes,
taps, spouts, valves, pumps, spray nozzles, moveable diaphragms,
and combinations thereof. Dispensers useful herein may include taps
such as press-taps. In one embodiment, the dispenser is a
self-venting press tap. Press taps useful herein include those
exemplified in U.S. Pat. No. 6,631,744 B1 assigned to Unilever,
U.S. Patent Application 2007/0290010 assigned to Vitop Moulding
S.R.I., and PCT Publication WO 2007/108025 assigned to Vitop
Moulding S.R.I.
[0044] Non-blow molded portions useful herein may include a
non-blow molded finish which may be retained as part of a preform
when a preform is utilized, or may be separately added or affixed.
In one embodiment, the non-blow molded finish is part of the
preform and the non-blow molded finish shape is retained while a
preform body portion is stretch blow-molded, resulting in a
container with a non-blow molded finish and a blow-molded portion
integrally connected. In FIG. 5, bridging FIG. 6, such an
embodiment is shown wherein the non-blow molded finish 82 is part
of the preform 60 also having a preform body portion 65. In FIG. 6
the resulting container is shown formed from the preform of FIG. 5,
maintaining the non-blow molded finish 82 and forming a blow-molded
portion 80 having sidewall 84.
Preform
[0045] In one embodiment, the container is formed from a
polypropylene preform and the blow molded portion has a hoop
blow-up stretch ratio of from about 4.5 to about 10, alternatively
from about 4.5 to about 8. As used herein "polypropylene preform"
includes preforms constructed all or in part from polypropylene
materials. The preforms useful herein will include the non-blow
molded portion and a body portion which may be blown through
standard blow-molding techniques, to create the blow molded
portion. In one embodiment, the body portion is polypropylene. In
another embodiment the preform is entirely polypropylene. Preforms
useful herein may be molded using any known molding method that is
capable of providing a polypropylene preform.
[0046] An example of a standard preform shape 10 useful herein and
having a non-blow molded finish is illustrated in FIG. 2 and in
cross-section to FIG. 2. The preform 10 comprises a non-blow molded
finish 11 a body 12, and a support ring 13, where the non-blow
molded finish 11 and body 12 are joined, and may be formed from a
single piece in a single blow molding operation. As illustrated,
the non-blow molded finish 11 exemplifies threads 14 which after
blow molding of the body portion 12 may be used to attach the
resulting container to a cap, dispensing or filling apparatus.
[0047] A cross-sectional view of a multi-layer preform shape 20
useful herein is illustrated in FIG. 3. The multi-layer preform 20
again has a body 12 and a non-blow molded finish 11, threads 14,
and a support ring 13. This multi-layer preform further has an
inner layer 15 and an outer layer 16. Preferably, when a
multi-layer preform is used herein, all layers will stretch during
blow molding without cracking, hazing or delaminating. In the
multi-layer preform illustrated in FIG. 3, the outer layer 16 does
not extend to the non-blow molded finish 11, but it may in some
embodiments, as illustrated in FIG. 4 and by preform 30.
Vibration Stability Test
[0048] In one embodiment, the containers of the present invention
pass a vibration stability test. The vibration stability test is
conducted by first subjecting the container to a vibration table
test according to ASTM D 4169 Level II, "Standard Practice for
Performance Testing of Shipping Containers and Systems". The
container passes the vibration stability test if after the
vibration table test, the container then passes at least a 2 ft,
preferably 3 ft drop impact test. The drop impact test is conducted
pursuant to that found in The Plastic Bottle Institute Technical
Bulletin PBI 4-1968, Rev'd 2-1988 following instructions for bottom
drop and filling with non-carbonated standard temperature water.
Preferably, the container can pass the 3 ft bottom drop test after
being subjected to a ASTM D 4169 Level I test.
[0049] Essentially, the container passes the vibration stability
test when the container can be subjected to the vibration test,
drop impact test, and does not leak water afterward.
Bottle-in-Box
[0050] In one embodiment, the container is at least partially
encompassed by an outer structural container, for example is part
of a bottle-in-box container.
[0051] In one embodiment, the outer structural container is a
corrugated board box.
Optional Finishes
[0052] The containers of the present invention may further include
one or more of the following optional finishes: a locator collar, a
handle, indication means for observing the amount of flowable
composition left within the container during use, area of weakness
for inserting a straw, and combinations thereof.
[0053] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0054] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0055] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *