Patent Publication Number: US-2006011715-A1

Title: Disposable container for liquids with molded liner

Description:
This application is a Divisional application of parent application Ser. No. 10/288,580, filed Nov. 6, 2002, which is still pending  
      This invention relates to a disposable container for liquids which includes an inner liquid impermeable liner which can be filled with a liquid and from which the liquid can be discharged and an outer shell member formed of a stiff sheet material having heat insulating properties. 
    
    
     BACKGROUND OF THE INVENTION  
      Containers of this type have recently become available primarily for “take-away” transporting coffee from gourmet coffee shops to a remote location such as an office for remote consumption. The conventional coffee cup limits the amount which can be carried and is inconvenient to carry a large amount of coffee for a large gathering such as at an office meeting.  
      However the container disclosed herein is not intended to be limited for use with coffee or other hot beverages and can be used for cold beverages or other liquids.  
      Six patents and applications of Andrews relating to this subject which are assigned to J&amp;M Coffee Container Company have been located which are U.S. Pat. Nos. 5,715,992; 5,909,841; 6,053,401; 6,196,452; 6,290,124 and U.S. Patent Application 2002/0047040. This discloses a container of this type which has an inner flexible liner formed from a flat bag with an attached fitment bonded or welded to the bag, and an outer stiff cardboard shell which carries the liner. It has the spout for filling and pouring from the liner in the front wall of the shell. The handle is formed as a folded cardboard handle integral with the outer shell.  
      Additional prior art patents U.S. Pat. No. 3,233,817 (Casady); U.S. Pat. No. 4,815,631 (Eeg) and U.S. Pat. No. 3,363,807 (Powell) all show similar arrangements.  
      A further patent of International Dispensing Corporation which is U.S. Pat. No. 6,375,040 (Allanson) issued April 2002 relates to a container of this general type haing a complex handle arrangement which supports an inner liner bag and an outer shell.  
      Yet further patents in this area also relate to beverage dispensing containers for gourmet coffee and these are U.S. Pat. No. 6,062,431 (Geshay) assigned to BIB Pak Inc.; U.S. Pat. No. 6,209,781 (Sylvester) assigned to Liberty Carton; U.S. Pat. No. 4,781,314 (Schoonover) which relates to a blow molded container and U.S. Pat. No. 2,954,901 (Winstead) which discloses a rectangular molded liner with an integral neck which is inserted within a rectangular box having a handle on one face. However the neck is not intended for a screw cap and the inner liner is molded in two halves and connected together along a diagonal seam.  
     SUMMARY OF THE INVENTION  
      It is one object of the present invention to provide an improved container for liquids of the type having an inner liner and an outer shell.  
      According to one aspect of the invention there is provided a container for liquids comprising:  
      an outer shell member formed of a stiff sheet material having heat insulating properties which can be erected from a flat storage condition into an outer shell defining a base, side walls and a top with a hollow enclosure;  
      an inner liquid impermeable lining member arranged to be contained within the hollow enclosure for containing the liquid such that when inserted into the outer shell, the outer shell member and the inner lining member can be commonly transported containing the liquid;  
      a handle exposed on an exterior of the container for manual transportation and lifting of the container;  
      at least one opening exposed on an exterior of the container communicating with an interior of the lining member for communication of the beverage through the opening, the opening having a neck with a threaded outer end for receiving a threaded closure cap thereon;  
      wherein the inner lining member including the neck and the opening is an integral molded one-piece body of a plastics material which can be collapsed from an erected condition substantially filling the hollow interior to a collapsed condition for transport.  
      The closure cap may be a simple cap which is itself closed or may be a valve or spigot which can be opened to allow controlled discharge of the liquid.  
      Preferably the inner lining member is blow molded which is a technique which readily and effectively forms a liner as an integral molded body formed wholly of plastics material, but other molding or forming methods may be used.  
      Preferably the inner lining member is semi-rigid so as to maintain an erected shape when inserted into the outer shell to prevent back-flow of liquid through the opening.  
      Preferably the inner lining member has a flat base and upstanding side walls. While the lining member is preferably rectangular in plan other more complex polygonal or curvilinear shapes may be used.  
      Preferably the inner lining member is collapsed by folding.  
      Preferably the inner lining member is semi-rigid to remain substantially in erected condition within the outer shell but collapsible under negative internal pressure to prevent glugging.  
      Preferably the handle is integrally molded with the inner liner member and projects through an opening in the outer shell member.  
      Preferably the handle forms a hand graspable member defining an opening between the handle member and a top wall of the inner lining member with each end of the handle member attached to the top wall. In this construction, the handle member preferably forms a hollow tube since this provides a stiff connection of the handle to the liner body. However solid handles can also be readily molded and used and may provide a stiff connection and firm support for the liner and thus the outer shell.  
      Preferably tubular handle member is pinched at one end to prevent contents of the lining member from entering the tubular handle member at that end.  
      Preferably the handle is on an inclined surface from one side toward the top and is parallel to the surface and thus itself inclined downwardly from the top since this provides an effective ergonomic support for the container when lifted for pouring.  
      Preferably the outer shell has top flaps at front and rear with the flaps being separate from the sides.  
      Preferably the outer shell has at least one slot thereon for passage through the shell of the handle member on inner lining member.  
      Preferably the outer shell has a separate attachment piece defining a container for accessories which can be attached to the container for transportation therewith.  
      Preferably the separate attachment piece includes a flap which hangs on an element of the inner liner member projecting through the outer shell, that is the neck or the handle.  
      Preferably there is provided an optional spigot/tap for attachment to the opening.  
      Preferably there is provided an optional tilt bottom formed from a foldable portion of the outer shell to lift one end of the outer shell for tilting the inner liner member toward the opening.  
      Preferably the inner lining member is translucent for viewing a fill level.  
      Preferably the inner lining member has a portion exposed through the outer shell and there are provided markings for identifying fill level.  
      Preferably the outer shell has an openable window for viewing the inner liner and there are provided markings on the outer shell for identifying fill level.  
      According to a second separate independent aspect of the invention there is provided a container for liquids comprising:  
      an outer shell member formed of a stiff sheet material having heat insulating properties which can be erected from a flat storage condition into an outer shell defining a base, side walls and a top with a hollow enclosure;  
      an inner liquid impermeable lining member arranged to be contained within the hollow enclosure for containing the liquid such that when inserted into the outer shell, the outer shell member and the inner lining member can be commonly transported containing the liquid;  
      a handle exposed on an exterior of the container for manual transportation and lifting of the container;  
      at least one opening exposed on an exterior of the container communicating with an interior of the lining member for communication of the beverage through the opening, the opening having a neck with a threaded outer end for receiving a threaded closure cap thereon;  
      wherein the handle is integrally molded with the inner liner member and projects through an opening in the outer shell member.  
      In this arrangement, preferably the outer shell has at least one slot thereon for passage through the shell of the handle member on inner lining member  
      In this arrangement, preferably the outer shell has top flaps only at front and rear with the flaps being separate from the sides.  
      According to a third separate independent aspect of the invention there is provided a container for liquids comprising:  
      an outer shell member formed of a stiff sheet material having heat insulating properties which can be erected from a flat storage condition into an outer shell defining a base, side walls and a top with a hollow enclosure;  
      an inner liquid impermeable lining member arranged to be contained within the hollow enclosure for containing the liquid such that when inserted into the outer shell, the outer shell member and the inner lining member can be commonly transported containing the liquid;  
      a handle exposed on an exterior of the container for manual transportation and lifting of the container;  
      at least one opening exposed on an exterior of the container communicating with an interior of the lining member for communication of the beverage through the opening, the opening having a neck with a threaded outer end for receiving a threaded closure cap thereon;  
      wherein the inner lining member is blow molded.  
      In this arrangement, preferably the inner lining member is semi-rigid so as to maintain an erected shape when inserted into the outer shell to prevent back-flow of liquid through the opening.  
      In this arrangement, preferably the inner lining member is collapsed by folding.  
      In this arrangement, preferably the inner lining member is semi-rigid to remain substantially in erected condition within the outer shell but collapsible under negative internal pressure to prevent glugging.  
      According to a fourth separate independent aspect of the invention there is provided a container for liquids comprising:  
      an outer shell member formed of a stiff sheet material having heat insulating properties which can be erected from a flat storage condition into an outer shell defining a base, side walls and a top with a hollow enclosure;  
      an inner liquid impermeable lining member arranged to be contained within the hollow enclosure for containing the liquid such that when inserted into the outer shell, the outer shell member and the inner lining member can be commonly transported containing the liquid;  
      a handle exposed on an exterior of the container for manual transportation and lifting of the container;  
      at least one opening exposed on an exterior of the container communicating with an interior of the lining member for communication of the beverage through the opening, the opening having a neck with a threaded outer end for receiving a threaded closure cap thereon;  
      wherein there is provided an optional tilt bottom formed from a foldable portion of the outer shell to lift one end of the outer shell for tilting the inner liner member toward the opening.  
      According to a fifth separate independent aspect of the invention there is provided a container for liquids comprising:  
      an outer shell member formed of a stiff sheet material having heat insulating properties which can be erected from a flat storage condition into an outer shell defining a base, side walls and a top with a hollow enclosure;  
      an inner liquid impermeable lining member arranged to be contained within the hollow enclosure for containing the liquid such that when inserted into the outer shell, the outer shell member and the inner lining member can be commonly transported containing the liquid;  
      a handle exposed on an exterior of the container for manual transportation and lifting of the container;  
      at least one opening exposed on an exterior of the container communicating with an interior of the lining member for communication of the beverage through the opening, the opening having a neck with a threaded outer end for receiving a threaded closure cap thereon;  
      wherein the outer shell has a separate attachment piece defining a container for accessories which can be attached to the container for transportation therewith.  
      In this arrangement, preferably the separate attachment piece includes a flap which hangs on an element-of the inner liner member projecting through the outer shell, that is the neck or the handle. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      One embodiment of the invention will now be described in conjunction with the accompanying drawings in which:  
       FIG. 1  is an isometric view from the front and one side of a first embodiment of container for liquids according to the present invention.  
       FIG. 2  is an isometric view from the rear and the opposite side of the first embodiment of  FIG. 1 .  
       FIG. 3  is a cross sectional view along a center line of the embodiment of  FIG. 1 .  
       FIG. 4  is an elevational view of the front sheet of the outer shell of the embodiment of  FIG. 1 .  
       FIG. 5  is an elevational view of the rear sheet of the outer shell of the embodiment of  FIG. 1 .  
       FIG. 6  is a side elevational view of the outer shell of the embodiment of  FIG. 1 .  
       FIG. 7  is an isometric view of the inner lining member of the embodiment of  FIG. 1 .  
       FIG. 8  is an isometric view of the inner lining member of a second embodiment.  
       FIG. 9  is an isometric view of a third embodiment. 
    
    
      In the drawings like characters of reference indicate corresponding parts in the different figures.  
     DETAILED DESCRIPTION  
      The container disclosed herein includes an inner liner member  10  and an outer shell  11 . The inner liner member  10  is formed to define a semi-rigid container with a flat base  12 , upstanding side walls  13 A,  13 B and  13 C and a top wall  14 . The container is substantially rectangular so that the side walls  13  are substantially vertical and substantially at right angles. The top wall  14  includes a flat top portion  15  and an inclined section  16  which extends downwardly from the top portion to the rear one of the side walls indicated at  13 C. The lining member  12  has at the top portion  15  a neck  17  with a screw thread for receiving a threaded cap  18 .  
      The liner member  10  further has a handle  20  standing up from the inclined upper portion  16  and defining a tubular handle member  21  which extends from the forward end  22  attached to the upper portion  16  to a rearward end  23  also attached to the upper portion  16  at the rear wall  13 C. The handle member is hollow and is integral with the liner member. The hollow tubular interior of the handle member connects with the hollow interior chamber of the liner member at the forward end  22 . At the rearward end  23  the handle member is pinched as indicated at  23 A so as to prevent communication of fluids between the hollow interior of the liner member and the handle.  
      The liner member is molded as an integral structure including the neck  17  and the handle  20 . This structure can be molded using the technique known as blow-molding in which a tubular portion of plastic material in partially molten form is fed into a mold which clamps at top and bottom and air is injected into the interior of the clamped tubular body so as to expand the plastics material onto the inside surface of the mold. The mold at the top where it clamps the plastic material clamps sufficient material to form the neck and the handle, with generally some flashing material which is subsequently cut off. The handle is formed as a tubular structure and its interconnection to the interior of the container allows the air injected into the interior of the container to also inflate the tubular plastics material at the handle so as to form the tubular handle as an integral continuous interior with the container without the necessity for separate injection into the handle. Thus air from the interior passes into the handles through the open forward end  22  where the rear end is pinched to close off the handle from the interior of the container.  
      Blow molding in this manner forms a structure which is semi rigid. This semi rigid container or liner member has the characteristics that when pulled into its rectangular shape it has sufficient strength to stand without collapsing. The handle stands firmly upwardly from the upper surface and does not flop to either side. However the structure can also be folded by compressing it downwardly so that the top surface including the handle and the neck is folded downwardly onto the bottom wall  12  with the side walls  13  folding inwardly. In this collapsed condition the container can remain folded so that its total volume is reduced to approximately to one quarter of the total volume when expanded to its full height. In this way when folded the containers can be packaged in relatively small volume for transportation and storage. In order to allow the folding, the side walls  13  are slightly bowed inwardly at the center as illustrated. The ability to fold and collapse requires the wall to be relatively thin and such walls are also therefore flexible so that they can flex inwardly when the pressure within the container reduces due to discharge of liquid. Thus liquid can be poured out from the container through the neck  17  by tilting the container without the necessity for the liquid to be replaced by air due to the collapsing of the container inwardly. This avoids the effect known as “glugging” where air is required to return into the container through the same opening thus interfering with the smooth flow of liquid out from the container when poured. Thus the container is semi-rigid and has walls that are sufficiently thin to flex but the walls have sufficient strength so that when expanded the walls hold the top surface away from the bottom surface. Thus the container when erected holds the opening at the neck  17  away from the base so that any liquid poured into the container when erected enters the space between the neck and the bottom surface preventing the bottom surface from causing backflow of liquid which can occur in a purely flaccid liner.  
      The outer shell  11  is preferably formed of cardboard as a stiff insulating material. The grade of material selected can vary depending upon the amount of insulation required. In one preferred example the grade of cardboard is of the type having inner and outer sheets with a corrugated section between the sheets thus defining an insulation space between the inner and outer sheets to improve insulation value. However simple paper board can be used in a situation where less insulation is required. Cardboard has the advantage that it can be folded from a flat storage condition to an erect use condition. However, other materials such as fabric or Styrofoam can also be used provided that they provide the necessary properties of sufficient stiffness and sufficient insulation.  
      The outer shell is formed from a folded and glued box structure using conventional box forming technology so that the box includes a bottom wall  30  which is self erecting and self foldable allowing the box to collapse diagonally with a bottom folding inwardly between the sides.  
      The outer shell  11  thus forms a rectangular container with vertical sides  31  including a front side  31 A a rear side  31 C and two sides  31 B. The sides  31 B in the folded condition collapse together by diagonal collapsing of the box about two opposed corners. In the erected condition the base snaps or connects together to form a flat base wall underlying and receiving the flat bottom  12  of the inner liner member.  
      The box or shell is shaped to substantially match the shape of the inner liner member. Thus there is a front wall  31 A which matches the height of the front  13 A of the liner. There is a rear  31 C matching the height of the rear  13 C of the liner. There is a top section which can be folded so as to lie over the upper surface  14  of the liner covering the upper surface and generally matching its inclination.  
      Thus the sides  31 B include flaps  35  and  36  which can be folded onto the top portion  15  and the incline portion  16  of the liner. A notch  37  divides the portions  35  and  36  so that they can fold about different fold lines. The fold line of the flap  35  is thus horizontal whereas the fold line of the flap  36  is inclined and co-planar with the upper surface  16  of the liner. The flaps  35  and  36  are arranged so that they, when folded, are spaced from the handle and the neck so as not to interfere with those elements when folded onto the top of the liner.  
      The front wall  13 A is shown in  FIG. 4  and includes a top flap  38  foldable about a fold line  39  which can be folded down onto the top portion  15 . The flap  38  includes an opening  40  shaped to surround the neck  17  allowing the neck to project through the opening  40 . The opening  40  has inwardly projecting elements which frictionally engage the sides of the neck so as to hold the flap down in place onto the neck when the flap is horizontal.  
      The rear surface is shown in  FIG. 5  and includes a fold line  42  separating the rear side  31 C from a flap  43 . The flap  43  includes two openings  44  and  45  each for engaging around a neck part of the handle member  20  with a slot  46  interconnecting the openings so that the slot can pass over the handle into the opening between the handle and the upper surface  16 .  
      Thus in operation, the shell can be stored in a folded condition with the sides flat and the fold lines formed by scoring or compression of the board material. The shell can then be erected by folding out the base so that the sides are moved to their positions at the sides of the rectangular shape and upstanding from the horizontal base  30 . In this erected condition, the liner member can be erected from its collapsed condition and inserted into the interior of the outer shell. With the liner in position, the side flaps are folded inwardly and then the flap  38  folded down over the neck and the flap  43  folded down over the handle so as to trap the flaps  35  and  36  underneath the flaps  38  and  43  to enclose the inner liner member within a closed outer shell. In this position, the handle projects through the outer shell so that the whole container can be lifted by the handle  20  which is integral with the inner liner. Also the neck  17  projects through the outer shell so that the cap  18  can be applied. Within the outer shell, the inner liner is erected or extended so that its bottom surface  12  lies against the bottom wall  30 .  
      This erected and assembled condition can be readily and quickly achieved by removing the collapsed pieces from a storage container and quickly assembling them manually to provide the assembled container.  
      On the side  31 B as shown in  FIG. 6  is provided a window  47  formed in the board material with a hinge line  48  on one side allowing the window to be opened to expose the liner within the shell. The liner is formed from a translucent plastics material so that a level of the liquid within the liner can be observed up to a required fill line. Markings  50  can be provided on the outer shell at the window so that various fill levels can be provided marking pre-determined quantities of liquid within the inner liner.  
      In use with the container in the erected and assembled condition, the cap  18  can be removed and liquid poured into the hollow interior of the inner liner. Because the inner liner is in an erected condition, there is no splash back or flow back of the liquid since it pours to the bottom of the inner liner thus readily being received within the inner liner up to a filled condition. When filled up to the required fill level as indicated by the markings  50 , the window can be closed and the cap  18  reapplied.  
      This arrangement has the following advantages:  
      a) The handle is integral on the inner liner so that the structure is more stable and the handle is more rigidly attached to the container as a whole as opposed to an arrangement in which the handle is merely a cardboard flap.  
      b) The neck is an integral part of the inner liner rather than an adhesively or otherwise attached separate piece.  
      c) The inner liner is sufficiently structured so that it is held and maintained open thus readily receiving the material when poured.  
      d) The integral liner has sufficient structural stability so that it can readily pass a “drop test” to avoid breakage and release of the contents.  
      e) The top flaps are of a simple construction simply folding over the handle and the neck so that they can be readily assembled.  
      f) When attached to the neck and the handle, the outer shell is stable and remains readily in place.  
      g) The handle is on the same incline as the inclined top surface so that it makes holding and pouring through the neck more simple.  
      h) There is a single opening in the inner liner so that the construction is very simple and can be readily sealed.  
      i) The fill level can be readily viewed.  
      j) The inner liner is sufficiently flexible so that the liquid can be poured while the liner collapses sufficiently to avoid glugging.  
      k) The liner member is formed by molding wholly from a suitable plastics material without the necessity for a laminate layer of foil or nylon or the like. Such foils are undesirable since they prevent recycling of the liner member and since they prevent heating of the container by microwave energy.  
      l) The molded liner member also allows cleaning and reuse of the container since whole of the interior of the liner can be readily washed through the opening at the neck.  
      m) The arrangement of the handle which is integral with the liner member provides more security for lifting hot liquids and provides an improved ergonomics of handling both for filling and pouring through the single opening at the neck. The location and inclination of the handle keeps the hand away from the hot steam at the neck and allows the user to readily tilt the container for pouring without unsuitable twisting of the wrist.  
      n) The use of a single opening for filling and pouring forms a simple and secure structure for handling hot liquids without danger of spillage. The location of the single opening allows the dispensing of the liquid by pouring or by draining using the optional spigot.  
      A first optional arrangement provides a container or caddy for accessories including cups and mixing materials such as sugar and cream. This container comprises a formed rectangular box  60  foldable in the same conventional manner as the main shell to define a base  61  and upstanding sides  62 . One of the sides  62 A has a top flap portion  63  which extends beyond an open mouth  64  of the box upwardly along the front face  31 A to a fold line  65  at which the flap can be folded along the top of the flap  38  to engage around the neck  17 . Thus the box or container  60  is hung off the neck along the front face and allows the transport of the accessories in a readily attached manner when the container is carried by the handle. The support of the accessories on the front avoids any interference with the handle and provides a reasonable balance of the weight of the structure. The engagement of the flap  66  around the neck provides a suitable attachment which allows sufficient weight to be carried within the container as required for the quantity of liquid within the container.  
      The accessory box  60  can be attached onto the container at any other suitable location suspended off the neck or the handle as required.  
      A second option is shown in  FIG. 3  and  4  and comprises a support leg  70  which can be moved to an erected condition shown in  FIG. 3 . The leg  70  is intended to be used with the accessory box removed and in an arrangement using an optional spigot in replacement for the cap  18 . Such spigots are well known and commercially available and can be applied while the opening  17  is upstanding as a replacement for or as an alternative for the simple closure cap. The spigot has a valve allowing liquid to be poured or dispensed. When the spigot is applied, the container can be rotated so that the wall  31 A lies on a support surface such as a table. The leg  70  thus raises the base  30  upwardly so that all of the liquid moves to the opening neck  17  and the spigot (not shown) allowing all of the liquid to be dispensed without the necessity for lifting the container and pouring the liquid.  
      The leg  70  is die cut from the front face  31 A so that it is provided as an integral part of the outer shell rather than as a separate piece. Different shapes of foldable leg can be provided as will be well know to one skilled in the art. However one preferred shape is shown in the drawings and provides a hinge line  71  at the bottom. The leg has a central hinge line  72  halfway across the leg so that it can be folded at that hinge line to form an apex  72 A which sits on the support surface when the container is rotated to the dispensing position. At the top of the leg  70  is provided a flap portion  73  which tucks in between two notches  74  when the leg is erected. Thus in the erection operation, the die cut leg is broken away from the front face and pulled outwardly about the hinge line  71  so that it forms a flap projecting outwardly from the front face. The flap is then bent around the hinge line  72  so that the flap portion  73  projects backwardly toward the surface  31 A. The flap  73  is then tucked back into the hole left by the removal of the flap at the notches  74 . Two wings  75  on the leg engage against the sides of the notches  74  so as to hold the leg in place with the apex projecting outwardly from the surface  31 A.  
      Alternative shapes of the structure are shown in  FIGS. 8 and 9 . Thus the inner liner member and its associated shell may not necessarily be rectangular but other more complex polygonal shapes can be used. In  FIG. 9 , the spigot indicated at  80  as shown is attached to the neck  17 .  
      In  FIG. 8 , the handle is shown on an inclined surface of the inner liner and this arrangement is preferred since the handle can then be molded as part of the same tubular structure in the blow molding process. However an arrangement less favorable is shown in  FIG. 9  in which the handle projects outwardly from the side of the inner container as indicated at  82 . In this arrangement the top surface is horizontal.  
      Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made within the spirit and scope of the claims without departing from such spirit and scope, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.