Beverage container

A unitary beverage container includes a main body defining a container volume. A flexible straw is fluidly connected at a proximal end with the volume adjacent the bottom of the main body. The flexible straw includes a series of segments which provide bending diaphragms. The straw also includes a distal end which is preferably in the form of a planar hollow mouthpiece having vertical wings and a central aperture therein with the mouthpiece is located adjacent the top of the main body. The segments of the straw near the bottom are strengthened and a curved portion of the straw has wedge shaped segments. An attaching mechanism removably attaches the distal end of the flexible straw to the top of main body and closes the aperture of the distal end. The attaching mechanism includes a short hollow bridge extending from the aperture at the distal end of the flexible straw which is broken during removal of the flexible straw to uncover the aperture prior to use. The hollow bridge is connected to a hollow chamber which is otherwise isolated fluidly from the container volume. A concavity in which the mouthpiece is received is provided at the top. A second attaching mechanism removably attaches the flexible straw to the main body.

FIELD OF THE INVENTION 
The present invention relates generally to beverage containers, and more 
particularly to a one-piece or unitary beverage container with an integral 
straw. 
BACKGROUND OF THE INVENTION 
Many different beverages are provided in various containers. Of particular 
use by small children are small beverage containers which are accessed by 
a straw. Typically, the straw is removably attached to the outside of the 
container and is separately wrapped. Thus, the straw can be lost making 
the beverage hard to consume. In addition, the loose straw and wrapper for 
the straw are potential problems with small children who might 
accidentally try to swallow them. These loose items are also a trash 
nuisance as they tend to be dropped. Further, many of these small beverage 
containers are made from multi-ply laminates which include paper, foil and 
plastic and are therefore not easily recyclable. 
A beverage container made of a synthetic resin and having a sipping tube or 
Straw connected to the container bottom is disclosed in U.S. Pat. No. 
4,982,854 (Ichimiya). A middle portion of the sipping tube is provided 
with a flexional bellows and the sipping tube is fitted into a 
longitudinal groove formed on the container body. 
Other patents have also disclosed various integral sipping tubes or straws. 
Among these are the following U.S. Pat. No. 4,607,755 (Andreozzi), U.S. 
Pat. No. 4,573,631 (Reeves), U.S. Pat. No. 4,830,204 (Lin), U.S. Pat. No. 
5,054,631 (Robbins), and U.S. Pat. No. 5,078,286 (Hashimoto). Other 
containers of general interest including various straw mounting means are 
shown in the following U.S. Pat. No. 5,005,717 (Oilar), U.S. Pat. No. 
3,332,567 (Pugh, St.), U.S. Pat. No. 4,669,608 (Thompson), and U.S. Pat. 
No. 4,712,702 (Ayabe et al.). 
SUMMARY OF THE INVENTION 
In accordance with the present invention, a unitary beverage container is 
provided which includes a main body defining a container volume in which a 
beverage is contained. The main body includes a top and a bottom, and 
attached to the main body is a flexible straw. The flexible straw includes 
a proximal end with which the straw is fluidly connected to the container 
volume adjacent the bottom of the main body. The flexible straw also 
includes a distal end formed as a mouthpiece having an aperture therein 
which is located adjacent the top of the main body. An attaching means is 
then provided for removably attaching the mouthpiece to the top of main 
body and for closing the aperture of the distal end of the flexible straw. 
According to a preferred embodiment of the invention, the attaching means 
includes a hollow chamber attached to the top and a short hollow bridge 
extending from the distal end of the flexible straw and about the aperture 
to the hollow chamber. This hollow bridge is broken during removal of the 
distal end of the flexible straw from the top whereby the aperture of the 
flexible straw is uncovered prior to use. In addition, the hollow chamber 
includes a solid connection to the top of the container such that the 
hollow chamber is in fluid communication with the container volume only 
through the flexible straw. Further, the hollow bridge includes a 
weakening thereof which makes the hollow bridge easily broken thereat by 
twisting of the distal end. This weakening of the hollow bridge is 
preferably a V-shaped notch circumferentially thereabout and radially 
directed toward a central longitudinal axis of the hollow bridge. 
In the preferred embodiment, the flexible straw is formed of a plurality of 
integral segments. Each integral segment is considered to (arbitrarily) 
comprise: an inner band, an outer band, an upper disk which connects the 
inner and outer bands together, and a lower disk which connects the outer 
band to the inner band of a preceding integral segment. With this 
construction, the disks form bending diaphragms to allow for the straw to 
bend as desired. In addition, the flexible straw extends along a side of 
the main body and along the top, so that the straw includes a curved 
section adjacent the junction between the side and the top. The inner and 
outer bands of the segments of this curved section are wedge shaped in a 
lateral and radial cross section of the curved section. The flexible straw 
is connected to the container volume adjacent the bottom. The inner bands 
of the portion of the flexible straw adjacent the proximal end have 
outside dimensions which decrease with the distance of the inner bands 
from the bottom. Other than at this bottom portion, the ratio of outside 
dimensions of the inner band to the outer band for a majority of the 
flexible straw is about 0.50 to 0.60, and most preferably about 0.55 to 
best provide for the bending diaphragm action of the disks. A second 
attaching means is also preferably provided to attach the flexible straw 
along the side of the main body. 
The distal end of the flexible straw preferably includes a hollow, flanged 
or flared mouthpiece having a top wing and an opposed bottom wing. These 
wings extend vertically from a longitudinal axis of an adjacent portion of 
the flexible straw and are used to twist the distal end so as to break the 
hollow bridge easily. With this configuration, the top of the main body 
includes a concavity in which the bottom wing is received. 
To effect filling of the beverage container, a filling tube or aperture may 
be provided which after filling may be crimped, sealed or otherwise closed 
off. After closure of a filling tube, excess material may be removed and, 
as shown in U.S. Pat. No. 5,078,286, hereby incorporated by reference, and 
as more particularly described hereinafter, the filling tube may be 
inverted into the main body of the container in order to provide a bottom 
surface free of projections. Another filling technique is as shown and 
described in the above-mentioned U.S. Pat. No. 4,982,854, hereby 
incorporated by reference, wherein a flanged filling aperture recessed 
within the bottom surface is sealed with an adhesive film after filling. 
It is an object of the present invention to provide a one-piece beverage 
container which does not have any loose parts even after opening which can 
become lost or accidentally ingested or swallowed by the user or others. 
It is also an object of the present invention to provide a one-piece 
beverage container which is easy to make, fill, and use. 
It is a further object of the present invention to provide a one-piece 
beverage container which stands up readily and which is easy to package 
together with other such beverage containers. 
It is a still further object of the present invention to provide a beverage 
container which does not spill easily. 
Another object of the present invention is to provide a beverage container 
and associated parts which are strong and which will not easily develop 
leaks. 
Other features and advantages of the present invention are stated in or 
apparent from a detailed description of a presently preferred embodiment 
of the invention found hereinbelow.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
With reference now to the drawings in which like numeral represent like 
elements throughout the views, a beverage container 10 is depicted in 
FIGS. 1-4 and 6-8. Beverage container 10 is designed to be blow molded 
from a synthetic resin or plastic such as low density or high density 
polyethylene, as a unitary or one-piece container formed in a single 
operation. Beverage container 10 includes a main body 12 which is 
rectangularly shaped with rounded corners in plan view and which defines a 
container volume 14 in which a beverage is contained. Typically, such 
beverages are fruit juices, fruit-flavored drinks or the like. With such 
beverages, the material of beverage container 10 is usually translucent so 
that the liquid level can be seen, and the material is colored the same or 
similar to the color of the beverage contained. In addition, suitable 
indicia or the like can be provided on the walls of main body 12 as part 
of the blow molding process if desired. Main body 12 has a top 16 
particularly shaped as described subsequently and a bottom 18 which is 
peripherally flat and somewhat recessed inside of the periphery so that 
beverage container 10 stands upright easily in normal use. 
In order to access the beverage in volume 14 of main body 12, an integral 
sipping tube or straw 20 is provided which is formed to be easily bendable 
(as discussed in detail subsequently). As shown in greater detail in FIG. 
9, straw 20 has a proximal end 22 which is integrally formed at a bottom 
corner 24 of main body 12. Straw 20 extends upwardly along a bevel surface 
26 of main body 12 provided above corner 24 and between the two adjacent 
sides. As will be appreciated from FIG. 8, bevel surface 26 is sized so 
that straw 20 stays inside of the silhouette of main body 12 when viewed 
from the bottom. 
Straw 20 is removably attached to bevel surface 26 by an attaching means 
28, which in this preferred embodiment is simply very thin connecting 
pieces forming an essentially continuous strip 30 between the outer 
portions of straw 20 and bevel surface 26 as shown best in FIG. 10. 
Preferably, these connecting pieces of strip 30 are simply formed in the 
blow molding process and are so thin as to be easily broken by the user 
when it is desired to detach all but proximal end 22 of straw 20 from main 
body 12. 
Straw 20 also includes a distal end 32 which is shaped into a mouthpiece 
34. Mouthpiece 34 may be hollow and planar shaped as shown in FIG. 11 with 
an upper wing 35a (only part of which is shown) and a lower wing 35b. This 
configuration is designed to be easily retained in the mouth of a user, 
particularly young children. In addition, mouthpiece 34 is provided with 
wings 35a and 35b so that wings 35a and 35b can serve as a fulcrum or 
twisting handle. By use of such a fulcrum, mouthpiece 34 is easily 
detached from an attaching means 36 by which mouthpiece 34 is attached to 
top 16 of main body 12. It will be appreciated that mouthpiece 34 has been 
depicted in a preferred shape, but that mouthpiece 34 could be provided in 
a variety of shapes consistent with its use as a fulcrum. Mouthpiece 34 
could also be made smaller so long as mouthpiece 34 is provided with 
sufficient surface area to serve as a fulcrum, and particularly the 
necessary finger gripping surface area for a thumb and forefinger. 
Mouthpiece 34 with wings 35a and 35b is depicted as hollow and planar in a 
vertical plane, which is easy to provide as mouthpiece 34 (and the 
remainder of beverage container 10) is blow molded. This hollowness 
results in a small amount of air which is drawn into the mouth each time 
that the user sucks on straw 20. Thus, if desired, mouthpiece 34 could be 
made less hollow or even solid with just a tubular conduit therethrough. 
However, a hollow mouthpiece 34 is nonetheless preferred as such a 
configuration is more comfortable in the mouth. In addition, by making 
mouthpiece 34 hollow, this hollowness and overall planar shape also 
contribute to the stiffness of mouthpiece 34 necessary for wings 35a and 
35b of mouthpiece 34 to serve as a fulcrum. Further, the existence of the 
hollow volume within mouthpiece 34 will reduce spillage from the container 
as the container is being opened and from the opened container in the 
event the container is knocked over. 
As shown best in FIG. 11, attaching means 36 includes a short hollow bridge 
38 extending from an aperture 40 provided in mouthpiece 34 to a connecting 
piece 42. The configuration of hollow bridge 38 is shown in greater detail 
in FIG. 11'. Thus, it will be appreciated that hollow bridge 38 is formed 
with a V-shaped notch 41 circumferentially thereabout which is radially 
directed toward a central longitudinal axis of hollow bridge 38 (and 
mouthpiece 34). Preferably, notch 41 is formed by an angle .phi. from 
vertical of about 30.degree.. V-shaped notch 41 provides a localized 
weakening of hollow bridge 38 which is easily broken by twisting of 
mouthpiece 34. This V-shaped notch 41 or other thinned portion is easily 
formed in the molding process as the material flows about the mold piece. 
The size of aperture 40 is not critical with respect to the sucking of the 
beverage from main body, although it obviously must be sufficient for a 
ready passage of a sufficient amount of the beverage when mouthpiece 34 is 
sucked on. However, the size of aperture 40 is important insofar as the 
larger the size, the greater the force which will be required to severe 
hollow bridge 38. Thus, a compromise is necessary for these competing 
objectives, and in beverage container 10 aperture 40 is preferably about 2 
to 4 mm. 
Connecting piece 42 of attaching means 36 is comprised of a hollow chamber 
43 securely attached to a concavity or recess 44 provided in top 16 of 
main body 12 by a solid connection in the form of a connecting wall 45. 
Hollow chamber 43 is hollow in order to form aperture 40 in mouthpiece 34 
during the blow molding process as beverage container 10 is formed. In 
particular, during the blow molding process, aperture 40 is formed as air 
passes through aperture 40 in order to subsequently form hollow chamber 43 
in connecting piece 42. Hollow chamber 43 is otherwise not in fluid 
communication with main body 12. Were connecting piece 42 not to include a 
hollow portion, the material forming connecting piece 42 would simply 
build up as a solid and aperture 40 would not be formed as desired. 
It will also be appreciated that it is important for hollow chamber 43 not 
to be in fluid communication with main body 12 except through straw 20. 
One reason is that if hollow chamber 43 was in fluid communication with 
main body 12, after mouthpiece 34 was removed, hollow chamber 43 would be 
a source of leakage from main chamber 12 in the event the container is 
knocked over or excessively squeezed during or after opening. 
Another reason for not having hollow chamber 43 in fluid communication with 
main body 12 other than through straw 20 is that leakage through straw 20 
upon opening and in use is actually reduced by this construction. This 
reduction of leakage in use is due to the fact that the beverage in main 
body 12 must be withdrawn by sucking on mouthpiece 34. This suction 
creates a negative pressure within main body 12. Consequently, when the 
user lets go of mouthpiece 34 or otherwise opens aperture 40 to atmosphere 
a residual negative pressure in main body 12 results in the liquid in 
straw 20 being drawn back toward main body 12. Typically, about half of 
the distal portion of straw 20 is then not filled with the beverage, and 
this is true even though the beverage height in main body 12 may be higher 
than that in straw 20. Thus, even if beverage container 10 falls over or 
is accidentally place on its side, due to the small size of aperture 40 in 
mouthpiece 34 and the lack of any other path for air to get into main body 
12, as well as the absence of any beverage near mouthpiece 34, there is 
not likely to be any leakage of the beverage from beverage container 10. 
As best shown in FIGS. 4 and 6, concavity 44 provided in top 16 of main 
body 12 extends along the entire corner-to-corner distance of top 16, and 
the shape of concavity 44 matches the profile of wing 35b of mouthpiece 
34. It should be appreciated that top 16 of main body 12 is reduced in 
height at the side adjacent to straw 20 so that the height of top 16 at 
this position and the height of straw 20 (together with the minimal height 
of the connecting pieces of strip 30) together equal the height of the 
remainder of top 16. Thus, straw 20 is also contained in the profile of 
top 16 as shown in FIG. 3. 
As mentioned above, mouthpiece 34 is easily detached from connection piece 
42 by breaking bridge 38 at notch 41. This is easily done by twisting 
mouthpiece 34 about its longitudinal axis (which is shared with the 
adjacent portion of straw 20), typically by placing a thumb on one side of 
wing 35a and a forefinger on an opposite side of wing 35b. Twisting by 
applying opposite forces to wings 35a and 35b causes bridge 38 to 
nonelasticly deform and break at notch 41 so that mouthpiece 34 can be 
lifted out of concavity 44. At the same time that mouthpiece 34 is lifted, 
adjacent connecting pieces of strip 30 are easily severed. The shape, size 
and orientation of wing or level elements, as well as the number of wing 
or lever elements, may be varied. 
Straw 20, as shown, is comprised of a plurality of interconnected 
bellows-like segments 21. The precise place where the repeating segments 
of straw 20 should be considered to stop and start is arbitrary, and has 
been selected as depicted and described simply for clarity. As shown best 
in FIG. 13 and according to one embodiment of this invention, each segment 
21 is considered to be composed of a series of integrally connected 
elements which are shown separated in FIG. 13 for clarity. Thus, the 
elements of each segment 21 are an inner band 60, an outer band 62, an 
upper disk 64 which connects inner band 60 to outer band 62, and a lower 
disk 66 which connects outer band 62 to an inner band 60 of a preceding 
segment 21 (not shown). 
The precise configuration of segments 21 has been particularly designed to 
allow straw 20 to bend easily and without developing leaks. With reference 
to FIG. 14, segment 21 is depicted with the elements thereof oriented as 
they would be when straw 20 is straight as shown by center line 68. This 
configuration is simply what segment 21 shown in FIG. 13 looks like when 
the elements are integrally connected. 
As shown in FIG. 15, the elements of segment 21 undergo some elastic 
bending when straw 20 is bent or curved as indicated by curved center line 
70. In particular, it will be appreciated that straw 20 is permitted to 
easily curve by the action of disks 64 and 66 which act as bending 
diaphragms. Thus, on the inside of the curve of straw 20, interior 
portions 72 of disks 64 and 66 bend toward one another and are slightly 
curved as shown; while on the outside of the curve of straw 20, interior 
portions 74 of disks 64 and 66 bend away from one another and are slightly 
curved in the opposite direction as shown. This bending diaphragm action 
of disks 64 and 66 is best seen by comparing FIGS. 14 and 15. Obviously, 
there is a smooth transition for each disk 64 and 66 between interior 
portions 72 and 74, as these portions have been depicted to show the 
extreme positions of disks 64 and 66 which most clearly show how bending 
is achieved with straw 20. 
The bending diaphragm action of disks 64 and 66 is achieved by making 
segments 21 of a configuration such that disks 64 and 66 are capable of 
the movement noted above. This movement is allowed by the material of 
segments 21 as well as the specific geometry. In order to achieve a 
suitable bending action, some trial and error testing is necessary with 
any given material and configuration of segments. However, it has been 
found that the ratio of the outside diameter of inner band 60 to the 
outside diameter of outer band 62 is an important consideration in 
achieving a suitable bending action. This ratio has been determined to 
preferably fall within the range of about 0.50 to 0.60, and most 
preferably is about 0.55. 
In addition, it has also been found that these segments 21 should be from 
1.3 to 5.5 mm. in length over the vertical section of straw 20. Such a 
dimension provides straw 20 with sufficient flexibility to facilitate use 
by the consumer while maintaining sufficient rigidity to enable straw 20 
to remain in an upright position after having been detached from both 
attaching means 30 and bevel surface 26 (as shown in phantom in FIG. 4). 
Preferably, segments 21 are about 2.2 to 3.2 mm. in height, and typically 
about 2.7 to 3.0 mm. in height. 
Additionally, as shown in the drawings, segments 21a should possess a 
generally triangular or wedge shaped side profile (or lateral and radial 
cross-sectional profile as shown in the broken away portion of FIG. 11) at 
curved straw portion 20a where straw 20 forms the approximately 90.degree. 
bend at the upper corner of main body 12. As shown best in FIG. 11, this 
wedge shape applies both to inner bands 60 as well as outer bands 62. It 
should also be appreciated that because segments 21a are otherwise 
configured similar to segments 21, curved straw portion 20a is bendable in 
the same manner as the rest of straw 20. Thus, curved straw portion 20a 
can be substantially straightened by the user if it is desired for straw 
20 to extend more or less straight as shown in chained lines in FIG. 4. 
While straw 20 is designed to be generally easily bendable, this is not 
true of stiffened straw portion 20b adjacent proximal end 22 of straw 20. 
Thus, as shown best in FIG. 9, the outer diameters of inner bands 60 of 
segments 21 are progressively smaller in an orderly manner to a minimum 
with increasing distance or height from proximal end 22. This causes 
segments 21b of stiffened straw portion 20b to become increasingly stiff 
the closer segment 21b is to proximal end 22, and thus stronger in order 
to withstand forces which would tend to concentrate thereat and pull 
stiffened straw portion 20b from corner 24 of main body 12. 
In order to fill beverage container 10, beverage container 10 may be 
initially provided with a filling tube 46 which initially extends from 
bottom 18 of main body 12 as shown in phantom in FIG. 4 and in FIG. 5. 
Filling tube 46 is cylindrically shaped, and due to the blow molding 
process of formation includes an apertured tip 48. Before the filling 
operation, tip 48 is cut off, such as at line 50, from the remainder of 
filling tube 46 to form a filling opening. In the filling operation, it 
will be appreciated that beverage container 10 is inverted from the 
orientation shown in the figures so that the beverage is easily introduced 
through filling tube 46 and retained in volume 14 by gravity. 
After filling, the end of filling tube 46 is heat sealed or crimped closed. 
Then, filling tube 46 is pushed or slammed by a plunger or the like so as 
to be partially inverted and thus located in the interior of main body 12, 
as shown best in FIG. 4. This is done while filling tube 46 is warm (at 
least because the beverage is hot) so that there is not much resistance to 
this movement. While there is some increase in pressure in main body 12 
caused by this inversion, this increase is more or less matched by a 
decrease in pressure as the hot beverage cools. 
This partial inversion is facilitated by the presence of inversion 
facilitating means 52 and 53. As best shown in FIG. 12, inversion 
facilitating means 52 is preferably a semicircular indentation 54 provided 
about filling tube 46 in bottom 18 of main body 12 which is readily and 
preferentially deformed as filling tube 46 is moved into the interior of 
main body 12. As best shown in FIG. 4, inversion facilitating means 53 is 
a sharply angled connecting portion 55 along filling tube 46 between the 
frustoconical portion which is inverted and the straight portion which is 
sealed. 
A benefit of filling inverted beverage container 10 through a bottom 
filling structure is that, as a result of lack of communication between 
hollow chamber 43 and main chamber 12, liquid does not flow into the straw 
so long as the fluid level does not rise to the proximal end 22 of straw 
20. When container 10 is returned to its upright orientation air contained 
in straw 20 will prevent fluid from rising up in straw 20. Thus, upon the 
initial opening of container 10, the likelihood of liquid being forced 
from distal end 32 of straw 20 is much reduced as both the empty volume of 
straw 20 and the empty volume within mouthpiece 34 would have to be 
overcome. 
After opening of container 10 the fluid level in the straw remains 
depressed as a result of the sub-atmospheric pressure present in the top 
headspace of main chamber 12. Low headspace pressure results from 
hot-filling of the liquid so that after sealing and cooling of container 
10, a partial vacuum is formed. When a consumer sucks liquid from 
mouthpiece 34 and then releases mouthpiece 34 to the atmosphere, external 
pressure will act to depress the liquid level in straw 20. Thus it can be 
seen that as a result of the container structure and hot filling the 
inverted container through a bottom structure, spillage, which could 
result from excessive squeezing of container 10 or form accidental tipping 
of container 10, is greatly minimized. 
In use, it will be initially appreciated that beverage container 10 is 
filled and sold to the consumer or user with a protective wrapping 
material (shrink wrap, plastic overlay, or the like) thereabout as well 
known by those of ordinary skill in the art. If desired, a number of 
beverage containers 10, such as six, can be bound together as a pack by 
the wrapping material. A cardboard sleeve may be positioned around such a 
pack inside of the wrapping material. 
After removal from the wrapping material, the user simply twists mouthpiece 
34. This is easily done due to the combined features of the flat shape of 
mouthpiece 34 with wings 35a and 35b, the concavity 44 provided, and the 
fact that wing 35a of mouthpiece 34 extends beyond straw 20. This twisting 
of mouthpiece 34 easily causes notch 41 of bridge 38 to break or shear 
apart. When this occurs, aperture 40 of mouthpiece 34 is exposed, and 
mouthpiece 34 can be lifted from concavity 44. As mouthpiece 34 is lifted 
from concavity 44, the connecting portions of strip 30 attaching the 
adjacent segment of straw 20 to top 16 are also easily broken or severed. 
Similarly, by continued pulling on straw 20, the remaining connecting 
portions of strip 30 along bevel surface 26 are severed so that straw 20 
can be moved by the user to any convenient position, such as that shown in 
phantom in FIG. 4. In this position, the user simply sucks on mouthpiece 
34 to drink the beverage in volume 14 of main body 12. 
It should be appreciated that mouthpiece 34 is easily retained in the mouth 
of the user due to its flat shape, which is especially advantageous for 
young children. In addition, by making straw 20 flexible, the user can 
play with the straw which is also an attraction for young children. 
Further, it should be appreciated that there are no loose parts of 
beverage container 10 which could become lost or accidentally ingested or 
swallowed. 
While the present invention has been described with respect to an exemplary 
embodiment thereof, it will be understood by those of ordinary skill in 
the art that variations and modifications can be effected within the scope 
and spirit of the invention.