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.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims benefit of U.S. Provisional Application Ser. No. 61/231,532, filed Aug. 5, 2009.

FIELD OF THE INVENTION

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

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.

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.

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.

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.

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.

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.

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

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.

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.

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.

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.

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.

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 μm/m²/day.

The present invention further relates to such containers wherein the container passes the vibration stability test.

The present invention further relates to such containers wherein the attachment means is selected from threads.

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.

The present invention further relates to such containers wherein the dispenser is a self-venting press-tap.

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.

The present invention further relates to such containers wherein the container is at least partially encompassed by an outer structural container.

The present invention further relates to such containers wherein the outer structural container is a corrugated board box.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a preform shape useful in the invention;

FIG. 2 illustrates the cross-section of the preform of FIG. 1;

FIG. 3 illustrates a cross-section of a multi-layer preform shape useful in the invention;

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;

FIG. 5 illustrates a cross-section of a preform inserted in a mold useful in the invention;

FIG. 6 illustrates a container blown from the preform of FIG. 5 useful in the invention.

DETAILED DESCRIPTION OF THE INVENTION

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

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.

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

The blow molded portion is integrally connected to a non-blow molded portion. As used herein, “integrally connected” means formed from a single preform.

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.

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.

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.

Polypropylene Thermoplastic Material

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.

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.

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 μm/m²/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° 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.

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

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).

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.

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.

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

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.

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.

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

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.

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

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.

In one embodiment, the outer structural container is a corrugated board box.

Optional Finishes

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.

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.”

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.

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.

Claims

1. A container comprising a blow molded portion and a non-blow molded portion integrally connected, wherein the blow molded portion comprises: wherein the non-blow molded portion further comprises an attachment means for connecting a dispenser.

(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;

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 μm/m2/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.