WO2023059578A1

WO2023059578A1 - Reinforced clamshell container and method of assembling same

Info

Publication number: WO2023059578A1
Application number: PCT/US2022/045597
Authority: WO
Inventors: Brennan BESSER; Oliver Seidel; Naurice JOSEPH
Original assignee: Eco Star, Llc
Priority date: 2021-10-05
Filing date: 2022-10-04
Publication date: 2023-04-13

Abstract

A reinforced container has an outer shell with a clamshell construction consisting of a first clamshell half and a second clamshell half, separated by a hinge region having a fold line. The outer shell includes a raised seam about its periphery, with a bottom gap in the raised seam. A bottom tab is coupled to the bottom surface of the outer shell at the bottom gap, spanning both the first and second clamshell halves. The bottom tab has a thickness that is substantially the same as the height of the raised seam of the outer shell above the bottom gap and proximate the bottom surface. The bottom tab serves to both further seal the first and second clamshell halves together and to provide balance to the outer shell, permitting the reinforced container to stand vertically above a supporting surface.

Description

REINFORCED CLAMSHELL CONTAINER AND METHOD OF ASSEMBLING SAME

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. provisional patent application Ser. No. 63/252,288, filed October 5, 2022, the entirety of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

The present invention relates, in general, to containers and, more particularly, to clamshell-type containers for storing and dispensing fluids, such as drinking water or other beverages.

BRIEF SUMMARY OF THE INVENTION

In one multilayered embodiment of the present invention, a reinforced container comprises an inner liner having an interior capable of storing and dispensing a fluid and an outer shell substantially surrounding the inner layer. The outer shell has a clamshell construction consisting of a first clamshell half and a second clamshell half, separated by a longitudinal hinge region having a fold line. The outer shell includes a raised seam about its periphery, with a bottom gap in the raised seam. A bottom tab is coupled to the bottom surface of the outer shell at the bottom gap, spanning both the first and second clamshell halves. The bottom tab has a thickness that is substantially the same as a height of the raised seam of the outer shell proximate the bottom surface. The bottom tab serves to both further seal the first and second clamshell halves together and to provide balance to the outer shell, permitting the reinforced container to stand vertically above a supporting surface. In an alternative embodiment of the present invention, the inner liner is eliminated. In this embodiment, the outer shell is substantially water impermeable. This may be accomplished by including an additive to the material that the outer shell is constructed of in order to make the overall shell water impermeable; by applying a substantially water impermeable material directly to the inner surfaces of the outer shell, or by constructing the outer shell entirely of a water impermeable material.

In such embodiments, a generally cylindrical spout fitment, preferably constructed of the same material as the outer shell, is affixed to the top of the outer shell and serves as a resealable pour spout. The spout fitment includes a bottom inlet and a top outlet communicating with the bottom inlet. The spout fitment further includes a neck region having a plurality of annular collars that mate with cooperating recesses in the interior of the outer shell in order to securely position the spout fitment at the top opening of the outer shell. A suitable adhesive may be employed to further secure the spout fitment in place, and to inhibit undesirable rotation of the spout fitment relative to the outer shell. An additional stop collar of the spout fitment abuts the top opening of the outer shell. External threads are disposed about the spout fitment proximate the outlet or spout. A cap, preferably made of the same material as the outer shell, includes internal threads that cooperate with the external threads of the spout fitment in order to resealably close the outer shell. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS FIG. 1 is a bottom perspective view of a multilayered embodiment of the present reinforced container;

FIG. 2 is bottom perspective view of the outer shell of the reinforced container of

Fig. 1;

FIG. 3 is a bottom perspective view of the inner liner of the reinforced container ofFig. 1;

FIG. 4 is a side view of the reinforced container of Fig. 1, shown during the assembly process;

FIG. 5 is side view of a spout fitment of an alternative embodiment of the present reinforced container; and FIG. 6 is a top perspective view of a resealable cap of the present reinforced container.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is susceptible of embodiment in many different forms, there is shown in the drawings and herein described in detail, several specific embodiments, with the understanding that the present disclosure is intended to be to an exemplification of the principles of the invention and not intended to limit the invention to the embodiments illustrated.

In one, multilayered embodiment the present invention comprises a reinforced container 10, which may function, for example, as a bottle for storing drinking water or other liquids or beverages, is shown in Figs. 1-4 as comprising outer shell 100, inner liner 200, and bottom tab 300. Outer shell 100 preferably has a single piece, unitary clamshell construction consisting of first clamshell half 110 and second clamshell half 120, joined by longitudinal hinge region 130 having a center fold line.

First clamshell half 110 has an exterior surface 111 and an internal cavity 113 that is generally half cylindrical in shape, with top and bottom regions that are generally hemispherical in shape. Second clamshell half 120 similarly has an exterior surface 121 and an internal cavity 123 that is generally half cylindrical in shape, with top and bottom regions that are generally hemispherical in shape.

First clamshell half 110 includes top opening 117, and second clamshell half 120 includes top opening 127. First clamshell half 110 further includes raised flange region 115 which extends about the majority of its periphery, with the exception of top opening 117 and bottom gap 116. Second clamshell half 120 likewise includes raised flange region 125 which extension about the majority of its periphery, with the exception of top opening 127 and bottom gap 126. Upon closing the clamshell halves of outer shell 100 by folding first clamshell half 110 and second clamshell half 120 towards each other along the center fold line of hinge region 130, top openings 117 and 127 come into abutment to form overall top aperture 150 of outer shell 100. Further, upon closing the clamshell halves of outer shell 100, raised flange regions 115 and 125 come into abutment with each other to form overall flanges of outer shell 100, with bottom gaps 116 and 126 adjacent each other to form overall bottom gap 140 of the flange surrounding the majority of outer shell 100 at bottom surface 160 of outer shell 100.

Outer shell 100 may be constructed of a recycled and/or recyclable paper material. In a preferred embodiment, a pulp material, such as a combination of bamboo and sugarcane (bagasse) pulp, may be used to form outer shell 100. A thermoforming process may be employed to shape the pulp into the form of outer shell 100. If desired, trademarks, text or other indicia may be embossed into the outer surface of outer shell 100 during the thermoforming process.

As best seen in Fig. 2, inner liner 200 includes generally cylindrical body 210, bottom hemispherical bottom 211, and a generally hemispherical top portion having neck region 220. Neck region 220 includes aperture 221, external threads 222 and collar 223. Although the size and capacity of inner liner 200 may be enlarged or reduced as desired, in a preferred embodiment, inner liner 200 has a fluid capacity of 100 milliliters, or approximately 16.9 fluid ounces. Other embodiments contemplated by the present invention include containers having 1 -liter and 1-galon capacities.

Inner liner 200 is preferably constructed of a plastic or thermoplastic material that is recycled and/or recyclable, such as a polyethylene terephthalate (“PET”)-based material. Additives may optionally be added to this material to speed biodegradation. Blow molding or another suitable process may be employed in constructing inner liner 200. In an alternative embodiment, inner liner 200 may consist primarily of a coating applied to the interior of outer shell 100, in combination with a spout. For example, inner liner 200 may alternatively comprise an eco-friendly, food-grade, spray-on (or otherwise applied) superhydrophobic coating with a lightweight spout fitment.

As shown in Fig. 1, bottom tab 300, which may comprise a glue tab, includes body 310 having generally disc-shaped central region 311 and two opposing wings 312. Notably, and as will be discussed below in association with the overall assembly of reinforced container 10, bottom tab 300 includes an overall length bisecting wings 312 that is substantially the same as the diameter of bottom surface 160 of outer shell 100. In addition, central region 311 has a diameter that is substantially the same as the width of bottom gap 116 and 126 of raised flange regions 115 and 125, respectively. Further, bottom tab 300 has an overall height, or thickness, substantially coinciding with the depth of bottom gap 116 and 126 of raised flange regions 115 and 125, respectively and, in turn, the depth of bottom gap 140 of outer shell 100. Bottom tab 300 is preferably constructed of the same material as outer shell 100, and may be attached to the bottom surface of container 10 using a suitable adhesive.

Referring to Fig. 6, a cap 460 of conventional design, having internal threads configured to be received by threads 223 of inner liner 200, may be used in conjunction with inner liner 200 to seal or retain drinking water or other fluids within the interior of inner liner 200. A generally cylindrical cap gripping cover may be disposed about the cap to facilitate the manual grasping and rotation of the cap. The cap gripping cover is preferably constructed of the same material as outer shell 100. Alternatively, the cap may have an overall unitary construction, and may be made, for example, of the same material as outer shell 100.

Referring to Fig. 4, reinforced container 10 is assembled beginning with outer shell 100 being in an open, substantially planar configuration, with longitudinal hinge region 130 in its open position. Inner liner 200 is inserted into interior cavity 113 of first clamshell half 110 of outer shell 100, which is sized and shaped to closely approximate and coincide with the exterior surface of inner liner 200. Next, a suitable adhesive is applied to at least one of the opposing surfaces of raised flange region 115 of first clamshell half 110 and raised flange region 125 of second clamshell half 120. Outer shell 100 is then closed upon itself, by bending longitudinal hinge region 130 along its center fold line, bringing clamshell halves 110 and 120 into abutment, with raised flange regions 115 and 125 adjacent each other. Heat and/or pressure may then be applied to further seal the clamshell halves to each other.

Next, referring to Fig. 1, bottom tab member 300 is applied to the bottom surface of outer shell 100, with wings 312 perpendicular to raised flange regions 115 and 125 of first clamshell half 110 and second clamshell half 120, respectively, and with central disc 311 disposed within bottom gap 140 of the bottom surface of outer shell 100, which is formed by the junction of bottom gap 116 of first clamshell half 110 and bottom gap 126 of second clamshell half 120. In this manner, wings 312 and raised flange regions 115 and 125 of first clamshell half 110 and second clamshell half 120 form a generally cruciform overall bottom surface of outer shell 100. A suitable adhesive, applied to bottom tab member 300 and/or the bottom surface of outer shell 100, may be employed to affix bottom tab member 300 to outer shell 100.

Notably, as the thickness of bottom tab member 300 is substantially the same as the depth of bottom gap 140 below the raised flange surrounding outer shell 100, upon the application of bottom tab member 300 to bottom gap 140, the outer surface of bottom tab member 300, together with the bottom edges of raised flange regions 115 and 125, collectively form a substantially planar, generally cruciform- shaped surface. In this manner, in addition to facilitating the more secure sealing of first clamshell half 110 and second clamshell half 120 to each other, the application of bottom tab member 300 to outer shell 100 provides balance and stability to reinforced container 10, permitting the overall container to be stood vertically upon its base, with each of the outer surface of bottom tab member 300 and the bottom edges of raised flange regions 115 and 125 being in substantially coplanar contact with a supporting surface.

In an alternative embodiment of the present invention, a separate inner liner, such as inner liner 200, is eliminated. In this embodiment, outer shell 100 is substantially water impermeable. This may be accomplished by including an additive to the material that the outer shell is constructed of in order to make the overall shell water impermeable; by applying a substantially water impermeable material directly to the inner surfaces of the outer shell, or by constructing the outer shell entirely of a homogeneous, water impermeable material.

In this embodiment, and as shown in Fig. 5, a generally cylindrical spout fitment

400 is provided. Spout fitment 400 is preferably constructed of the same material as outer shell 400, and affixed to the interior of outer shell 400, proximate top aperture 150, and serves as a resealable pour spout. Spout fitment 400 includes bottom inlet top outlet 420 communicating with bottom inlet 410. Spout fitment 400 further includes neck region 430 having a plurality of annular collars 435 that mate with cooperating recesses in the interior of first clamshell half 110 and second clamshell half 120, in order to securely position spout fitment 400 at top aperture 150 of outer shell 100.

A suitable adhesive may be employed to further secure spout fitment 400 in place, and to inhibit undesirable rotation of spout fitment 400 relative to the outer shell 100. An additional stop collar 435 of spout fitment 400 abuts top aperture 150 of outer shell 100. External threads 450 are disposed about spout fitment 400 proximate outlet or spout 420. As shown in Fig. 6, cap 460, preferably made of the same material as outer shell

100, is provided in order to provide a resealable feature to spout fitment 400 and to container 100 as a whole. Cap 460 includes internal threads that cooperate with external threads 450 of spout fitment 400 in order to resealably close container 10.

The preceding description and drawings merely explain the invention and the invention is not limited thereto, as those of ordinary skill in the art who have the present disclosure before them will be able to make changes and variations thereto without departing from the scope of the present invention.

Claims

CLAIMS What is claimed is:

1. A reinforced container comprising: a shell having a clamshell construction consisting of a first clamshell half and a second clamshell half, the first and second clamshell halves being separated by a hinge region having a fold line; the first clamshell half having a first raised seam, a first bottom surface, and a first bottom gap in the first raised seam at the first bottom surface; the second clamshell half having a second raised seam, a second bottom surface, and a second bottom gap in the second raised seam at the second bottom surface; the first raised seam, first bottom surface, and first bottom gap abutting the second raised seam, second bottom surface, and second bottom gap, respectively, to form an overall raised seam, bottom surface, and bottom gap of the outer shell, respectively; and

A bottom tab coupled to the bottom surface of the outer shell at the bottom gap, the bottom tab having a thickness that is substantially the same as a height of the raised seam of the outer shell proximate the bottom surface, the bottom tab serving to both further seal the first and second clamshell halves together and to provide balance to the shell, permitting the reinforced container to stand vertically above a supporting surface.

2. The reinforced container according to claim 1, wherein a portion of the first raised seam, a portion of the second raised seam, and a bottom surface of the bottom tab collectively form a substantially planar surface.

3. The reinforced container according to claim 1, wherein a portion of the first raised seam, a portion of the second raised seam, and a bottom surface of the bottom tab collectively form a substantially cruciform shape.

4. The reinforced container according to claim 1, wherein the shell is constructed of a paper-based material.

5. The reinforced container according to claim 1, wherein the bottom tab is constructed of the same material as the shell.

6. The reinforced container according to claim 1, further including a spout fitment proximate a top opening of the shell.

7. The reinforced container according to claim 1, wherein the spout fitment is affixed to inner surfaces of the first clamshell half and the second clamshell half.

8. The reinforced container according to claim 1, further including an inner liner having an interior capable of storing and dispensing a fluid.