CONTAINERS FOR HOLDING MATERIALS

Abstract

A liquid container comprises a liquid holding bag, a drain-back pour spout in fluid communication with the liquid holding bag, and a skeleton shell for supporting the liquid holding bag, the skeleton shell formed of a low-embodied energy material, such as a molded fiber or pulp-formed material. The liquid container can be configured for holding and dispensing a detergent.

Description

CROSS-REFERENCE

This application claims priority to U.S. Provisional Patent Application No. 61/421,192, filed on Dec. 8, 2010, which is entirely incorporated herein by reference.

BACKGROUND OF THE INVENTION

Packaging used for containing liquids can generate large amounts of waste. In some cases, packaging used for containing liquids can be recycled. Packaging used for containing liquids has been described in PCT Publication No. WO/2007/0066090, which is herein incorporated by reference in its entirety.

Traditionally, many beverages such as wine, beer and milk have been supplied in glass bottles. The glass used to make these bottles may itself be recycled. However, the energy required to make the bottles is high. Also, the weight of the resulting packaging is high, increasing the amount of energy required to transport the products. While the glass can be recycled, this does require that the bottles are separated from other waste, for example by users separating the glass bottles from other household waste for collection. Therefore, it is often the case that glass bottles are disposed of with other waste. In this case, the glass bottles may be disposed of in a landfill site. This is a problem since, unlike some other forms of waste, glass is not biodegradable.

More recently, it has become common to use bottles made from plastics, such as PET or HDPE, for liquid such as water, juice, carbonated drinks, or milk. In this case, it is common for the bottles to be formed from virgin, i.e. non-recycled, material to ensure that the liquid contained within the bottle is not contaminated as could be the case if the containers were formed from recycled material. While the material itself could be recycled if separated from other waste, as with glass bottles this frequently does not occur due to the need for the waste producer, such as a householder, to separate the containers from other waste material. Again, if the container is disposed of in a landfill site or the like, the bottle is not biodegradable. Also, bottles take up a volume larger than that of the material itself due to their hollow, rigid, structure, and therefore take up an excessive amount of space in a landfill site.

It has also been proposed to package liquid in laminated cardboard containers, for example in containers marketed by Tetra Pak. In this case, the cardboard from which the body of the container is formed may be virgin or recycled material. The cardboard is laminated with a waterproof coating. This ensures that the container is able to hold liquid and also acts as a barrier between the liquid and the cardboard, which can prevent contamination of the liquid from the cardboard. This is especially needed where the cardboard is formed from recycled material. A problem with such packages is that they are difficult to recycle, and the waterproof coating prevents them fully decomposing. The problem is exacerbated when a plastic dispensing nozzle or cap is formed as part of the package for dispensing the contents. This is another component that would need to be separated before the container can be recycled or parts of this be allowed to decompose.

In some countries, liquid such as milk is packaged in bags. However, these bags have little structural stability, and therefore are difficult to transport and to stack on shelves. They are often not re-sealable, making them hard to hold and carry.

It is known to package wine in boxes. These comprise a box body, typically formed of laminated cardboard, which provides the structure for the package. A bag is provided within the box, the wine being contained within the bag. A dispensing tap is often connected to the bag, and when in use is arranged to protrude through a side opening in the box. In such instances, the spout is made to protrude or hang outside of the box for dispensing. The weight of the liquid is usually distributed along the box bottom and is not supported by the dispensing tap protruding from the box. For the efficient disposal of such a container, each of the parts made from different materials would be also separated, namely the bag from the box, the dispensing tap from the bag, and the lamination from the cardboard forming the box. This separation of packaging components is difficult and prevents such packages from being disposed of or recycled efficiently.

Furthermore, in some cases bottles or other liquid containers contain additional, separable components that do not make it into a recycling bin. For example, loose caps, straws, and plastic tamperproof or tamper-evident devices can contribute to overall litter in the environment. Even if bottles make it into a recycling bin or garbage can, their caps or other types of closures often end up as general litter.

SUMMARY OF THE INVENTION

In view of the limitations of containers currently available in the art, recognized herein is a need for improved containers that have a reduced negative impact on the environment while providing consumers with enhanced functionality and design features.

An aspect of the invention provides a liquid container, comprising a liquid holding bag, a drain-back pour spout in fluid communication with the liquid holding bag, and a skeleton shell for supporting the liquid holding bag, the skeleton shell formed of a molded fiber or pulp-formed material. In an embodiment, the skeleton shell comprises a first side member and second side member. In another embodiment, the drain-back pour spout is formed from a polymeric material. In another embodiment, the drain-back pour spout is disposed at a top portion of the liquid holding bag. In another embodiment, the liquid holding bag is formed from a polymeric material. In another embodiment, the liquid container has a thickness between about 0.001 inches and 0.025 inches. In another embodiment, the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.

Another aspect of the invention provides a low embodied energy liquid container, comprising a liquid holding bag, a drain-back pour spout in fluid communication with the liquid holding bag, and a skeleton shell for supporting the liquid holding bag, the skeleton shell formed from a low embodied energy material. In an embodiment, the low embodied energy material comprises molded fiber or a pulp-formed material. In another embodiment, the low embodied energy material comprises 25-100% pulp by weight of the skeleton shell. In another embodiment, the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.

Another aspect of the invention provides a detergent bottle comprising a fitment welded to a detergent holding bag, the detergent holding bag having a thickness between about 0.001 inches and 0.025 inches.

Another aspect of the invention provides a detergent bottle comprising a spout attached to a detergent holding bag, the detergent holding bag having a thickness between about 0.001 inches and 0.025 inches. In an embodiment, the spout comprises a removable sealing member at an opening of the drain-back pour spout.

Another aspect of the invention provides a method for assembling a liquid holding container, comprising enclosing a liquid holding bag in a low embodied energy skeleton shell, the liquid holding bag comprising a drain-back pour spout. In an embodiment, the liquid holding bag has a thickness between about 0.001 inches and 0.025 inches. In another embodiment, the drain-back pour spout is disposed at a top portion of the liquid holding bag. In another embodiment, the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.

Another aspect of the invention provides a container comprising a pour spout and a skeleton shell attached to the pour spout, the skeleton shell formed of a low embodied energy material. In an embodiment, the low embodied energy material comprises molded fiber or a pulp-formed material. In another embodiment, the pour spout includes a drain-back pour spout. In another embodiment, the pour spout includes registration members for locking the pour spout to one or more surfaces of the pour spout. In another embodiment, the pour spout is for dispensing an edible or inedible liquid. In another embodiment, the pour spout is for dispensing an edible or inedible solid. In another embodiment, the container further comprises a fitment for attachment to the skeleton shell. In another embodiment, the pour spout comprises a removable sealing member at an opening of the pour spout.

Another aspect of the invention provides a container comprising a skeleton shell formed of a molded fiber or pulp-formed material and a drain-back pour spout at an opening of the skeleton shell. In an embodiment, the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.

Additional aspects and advantages of the present disclosure will become readily apparent to those skilled in this art from the following detailed description, wherein only illustrative embodiments of the present disclosure are shown and described. As will be realized, the present disclosure is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, all without departing from the disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature, and not as restrictive.

INCORPORATION BY REFERENCE

All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the invention may be further explained by reference to the following detailed description and accompanying drawings that sets forth illustrative embodiments.

FIG. 1 is a diagram of a container comprising a molded fiber or pulp-molded skeleton, a liquid holding bag, in accordance with an embodiment of the invention;

FIG. 2 is a schematic-side view of the container of FIG. 1, in accordance with an embodiment of the invention;

FIGS. 3A and 3B illustrate a skeleton shell, in accordance with an embodiment of the invention; FIG. 3C illustrates a liquid holding bag in the skeleton shell of FIGS. 3A and 3B, in accordance with an embodiment of the invention;

FIG. 4 is a schematic side view of a drain-back pour spout, in accordance with an embodiment of the invention;

FIG. 5 shows a drain-back pour spout mounted on neck portion of a skeleton shell, in accordance with an embodiment of the invention;

FIG. 6A is a schematic side view of a drain-back pour spout, in accordance with an embodiment of the invention; FIG. 6B is a schematic top view of the drain-back pour spout of FIG. 6A, in accordance with an embodiment of the invention;

FIG. 7A is a schematic side view of a drain-back pour spout having a cap, in accordance with an embodiment of the invention; FIG. 7B is a schematic side view of a drain-back pour spout, in accordance with an embodiment of the invention;

FIG. 8A is a schematic top view of a drain-back pour spout, in accordance with an embodiment of the invention; FIG. 8B is a schematic bottom view of the drain-back pour spout of FIG. 8A, in accordance with an embodiment of the invention;

FIGS. 9A and 9B schematically illustrate a drain-back pour spout having registration members, in accordance with an embodiment of the invention; and

FIGS. 10A-10D schematically illustrate a pour spout having a removable sealing member, in accordance with an embodiment of the invention; and

FIGS. 11A-11D schematically illustrate the pour spout of FIGS. 10A-10D in which the removable sealing member has been removed from the pour spout, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

While preferable embodiments of the invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention.

The invention provides for containers comprising a material holding vessel (e.g., liquid holding bag, liquid container), a closure and a skeleton. The container components, including the holding vessels, fitments, closures and skeletons described herein can be interchanged or combined with various illustrations of the invention. Any of the aspects of the invention described herein can be combined with other container components known to those skilled in the arts.

The containers described herein can be used for the delivery and/or storage of liquids for human consumption or for the delivery and/or storage of liquids not for human consumption. Examples of materials that can be contained include soaps, detergents, edible oils, such as olive oil and canola oil. In an embodiment, materials that can be contained include soaps and detergents.

The term “detergent”, as used herein, can include any liquid or non-liquid (e.g., solid, such as a powder) having a surfactant or a mixture of surfactants having cleaning properties in dilute solutions. For example, soaps are surfactants and detergents. A detergent can include alkylbenzenesulfonates. A detergent can include laundry detergent, dish detergent and hand soap. In an embodiment, a detergent can include an anionic compound, such as a sulfonate, including alkylbenzenesulfonate. In another embodiment, a detergent can include a cationic compound, such as a quaternary ammonium-containing compound, including quaternary ammonium salts and quaternary ammonium compounds. In another embodiment, a detergent can include an ethoxylate compound, which can include a compound terminating in an (OCH₂CH₂)_nOH group. In another embodiment, a detergent can include a non-ionic (or zwitterionic) compound. In another embodiment, a detergent can include a non-liquid. In another embodiment, a detergent can include a solid (e.g., powder).

The term “embodied energy”, as used herein, can refer to the total energy required to produce a product from the raw materials of the product. In some cases, embodied energy can refer to the total energy required to produce a product from the raw materials of the product, and deliver the product. Based on the processes used to form materials, one material can have an embodied energy that is larger than that of another material.

In an embodiment, the liquid holding vessel can be coupled to a structural chassis or skeleton to support the vessel during shipping and handling. The liquid can be dispensed from the container by pouring, sucking, squirting, or other means. The structural chassis can prevent collapse of the vessel and resist side force on the container sufficient to allow the container to be picked up in one hand and the beverage to be dispensed in a controlled fashion.

Containers

In an aspect of the invention, a container is provided. The container can be configured to store and dispense a liquid, non-liquid (e.g., solid). In an embodiment, the container can be configured to store and dispense a detergent. In some embodiments, the container comprises a holding bag for holding (or storing) a liquid or solid, a drain-back pour spout in fluid communication with the holding bag, and a skeleton shell (also “skeleton” and “shell” herein) for supporting the holding bag.

In some embodiments, a container is provided comprising a pour spout and skeleton shell. In an embodiment, the pour spout can be a drain-back pour spout. In another embodiment, the spout can include registration members for locking the spout against the skeleton shell. In another embodiment, the skeleton shell can be formed of a low-embodied energy material, such as molded fiber or pulp-formed material. In an embodiment, the container includes a pour spout and skeleton shell but no holding bag (or liner). In another embodiment, the container includes a pour spout and skeleton shell but no liquid holding bag (or liner). In another embodiment, the container includes a pour spout and skeleton shell but no holding bag attached to the pour spout. In another embodiment, the liquid container includes a pour spout and skeleton shell but no liquid holding bag attached to the pour spout.

In some embodiments, a container is provided comprising a pour spout, fitment and skeleton shell. The fitment can be integral to (or unitary with) the pour spout. In an embodiment, the fitment can be configured to attach the spout to the skeleton shell. In another embodiment, the fitment can be configured to mate with the skeleton shell. In another embodiment, the fitment can include registration members for locking the spout or fitment against the skeleton shell. In another embodiment, the pour spout can be a drain-back pour spout. In another embodiment, the skeleton shell can be formed of a low-embodied energy material, such as molded fiber or pulp-formed material. In an embodiment, the container includes a pour spout and skeleton shell but no holding bag (or liner). In another embodiment, the container includes a pour spout and skeleton shell but no liquid holding bag (or liner). In another embodiment, the container includes a pour spout and skeleton shell but no holding bag attached to the pour spout. In another embodiment, the liquid container includes a pour spout and skeleton shell but no liquid holding bag attached to the pour spout.

In an embodiment, a container comprises a fitment. The fitment can be configured to mate with the skeleton shell. In an embodiment, the fitment comprises one or more flanges for mating with (or attaching to) the skeleton shell. In another embodiment, the fitment comprises registration features for preventing or minimizing rotation of the liquid holding bag while disposed in the skeleton shell. In another embodiment, the fitment is formed of registration features for preventing or minimizing rotation of the liquid holding bag while disposed in the skeleton shell.

A bag can be attached to a shell using a variety of mechanisms. These mechanisms can include attachment of the bag to the shell or skeleton by a fitment. The fitment can be attached to the shell through the use of heat, welding, glue, flanges, interlocking connections, friction, snaps, locks, clips, rails, mechanical deformation, or any other mechanism known to one skilled in the art.

In some embodiments, a container comprises a bag and a fitment comprising a collar for holding a neck of the bag to a skeleton shell. The collar can provide a frictional fitting around both the skeleton and the neck. This may prevent or minimize rotation of the bag within the skeleton. In some situations, the collar locks the neck of the bag against the skeleton shell, thereby preventing appreciable rotation of the neck upon a user screwing and unscrewing a cap of the container.

In an embodiment, a container comprises a spout, fitment and skeleton shell, the fitment for mating with the skeleton shell. In another embodiment, a container comprises a spout, fitment and skeleton shell and no holding bag (or liner), the fitment for mating with the skeleton shell.

Containers provided herein can be configured for storing and dispensing various liquids, such as, detergents. Containers can be configured for storing and dispensing other liquids, such as fruit juice (e.g., apple juice, orange juice, grape juice), milk, carbonated liquids (e.g., soda beverages), wine, beer, edible oils and water. In the case of wine, various containers provided herein can contain skeletons in the shape of carafes. Containers can be configured for storing edible and inedible materials, including edible and/or inedible solids (on non-liquids), liquids, or solid-liquid mixtures.

In an embodiment, a container is provided for storing a liquid or non-liquid (e.g., solid or powder). In another embodiment, a container is provided for storing a detergent, such as a liquid detergent or solid detergent. In another embodiment, a container is provided for storing a wet detergent or dry detergent. In another embodiment, a container is provided for storing a solid, such as a powder (e.g., chemicals, salt, rice, cereal, oatmeal). In another embodiment, a container is provided for storing a gel or gel-like material. In another embodiment, a container is provided for storing one or more solid objects. In another embodiment, a container is provided for storing an edible liquid or solid. In another embodiment, a container is provided for storing an inedible liquid or solid.

In an embodiment, the liquid container comprises a fitment. The fitment can be configured to mate with the skeleton shell. In an embodiment, the fitment comprises one or more flanges for mating with (or attaching to) the skeleton shell. In another embodiment, the fitment comprises registration features or registration members for preventing or minimizing rotation of the liquid holding bag while disposed in the skeleton shell.

In an embodiment, a container comprises registration members for preventing or minimizing movement of a spout, fitment, or both, while the spout or fitment is mated to a skeleton shell of the container. Such movement can be rotational movement, vertical movement (i.e., movement along an axis orthogonal to a base of the container), or horizontal movement (i.e., movement along an axis parallel to a base of the container).

In an embodiment, the liquid container comprises a fitment between the liquid holding bag and the drain-back pour spout. In another embodiment, the fitment is integrally part of the drain-back pour spout. For example, the drain-back pour spout can include a flange configured to mate with (or attach to) the skeleton shell, and registration features, as described above. In another embodiment, the spout and fitment are single piece (or unitary). In another embodiment, the spout is single-piece (or unitary) with the fitment.

In an embodiment, the skeleton shell is formed of a molded fiber or pulp-formed material. In another embodiment, the skeleton shell is formed of a low-embodied energy material. Such material can include any material formed in a manufacturing process configured to minimize energy use.

In an embodiment, the skeleton shell comprises a first side member and second side member. One or both of the first and second side members can be configured to permit a user to hold or grip the skeleton shell. A side member can include a grip area to permit a user to grip the skeleton shell. The grip area can be a depression in the side member. In some cases, the depression can have a cross-section that is circular, oval, triangular, square, rectangular, or other shape. In some situations, the grip area can be processed such that it provides a user comfort when held or gripped by the user.

In an embodiment, the drain-back pour spout is formed from a polymeric material. In another embodiment, the drain-back pour spout can be formed of one or more of linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene (HDPE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and polystyrene (PS).

In an embodiment, the drain-back pour spout can be formed by injection molding. In another embodiment, the drain-back pour spout can be machined from a polymeric material. In another embodiment, the drain-back pour spout can be machined from a single-piece polymeric material. In another embodiment, the drain-back pour spout and fitment can be machined or injection molded separately and attached to one another. In another embodiment, the drain-back pour spout and fitment can be machined or injection molded from a single piece material, such as a single polymeric material.

In an embodiment, the liquid holding bag is formed of a polymeric material. In another embodiment, the liquid holding bag is formed from a flexible material. In another embodiment, the liquid holding bag can be formed of one or more of linear low density polyethylene (LLDPE), low density polyethylene (LDPE), high density polyethylene (HDPE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC) and polystyrene (PS).

In an embodiment, the liquid holding bag has a thickness between about 0.001 inches and 0.025 inches. In another embodiment, the liquid holding bag can have a thickness of about 0.001 inches, or 0.002 inches, or 0.003 inches, or 0.004 inches, or 0.005 inches, or 0.006 inches, or 0.007 inches, or 0.008 inches, or 0.009 inches, or 0.01 inches, or 0.011 inches, or 0.012 inches, or 0.013 inches, or 0.014 inches, or 0.015 inches, or 0.016 inches, or 0.017 inches, or 0.018 inches, or 0.019 inches, or 0.02 inches, or 0.021 inches, or 0.022 inches, or 0.023 inches, or 0.024 inches, or 0.025 inches, or 0.026 inches, or 0.027 inches, or 0.028 inches, or 0.029 inches, or 0.030 inches.

In an embodiment, a liquid container is configured to hold or store between about 1 ounce and 500 ounces of a liquid, or between about 10 ounces and 200 ounces of liquid, or between about 20 ounces and 100 ounces of liquid, or between about 30 ounces and 80 ounces of liquid.

In an embodiment, a liquid container is configured to hold or store between about 1 ounce and 500 ounces of a detergent, or between about 10 ounces and 200 ounces of liquid, or between about 20 ounces and 100 ounces of a detergent, or between about 30 ounces and 80 ounces of a detergent.

In an embodiment, a liquid container comprises a liquid holding bag having a capacity between about 1 ounce and 500 ounces, or between about 10 ounces and 200 ounces, or between about 20 ounces and 100 ounces, or between about 30 ounces and 80 ounces.

In an embodiment, the drain-back pour spout is disposed at a top portion of the liquid holding bag. In another embodiment, the drain-back pour spout is attached to a top portion of the liquid holding bag. In another embodiment, the drain-back pour spout is welded to a top portion of the liquid holding bag. In another embodiment, the drain-back pour spout is attached to a fitment. In another embodiment, the drain-back pour spout is welded to a fitment. In another embodiment, the drain-back pour spout is attached to a fitment that is attached to the liquid holding bag.

In some embodiments, a low embodied energy liquid container is provided, the low embodied energy liquid container comprising a liquid holding bag, a drain-back pour spout in fluid communication with the liquid holding bag, and a skeleton shell for supporting the liquid holding bag, the skeleton shell formed from a low embodied energy material. In an embodiment, the low embodied energy material can comprise molded fiber or a pulp-formed material. In another embodiment, the low embodied energy material can have a pulp composition, by weight of the skeleton shell, of up to about 25%, or 30%, or 35%, or 40%, or 45%, or 50%, or 55%, or 60%, or 65%, or 70%, or 75%, or 80%, or 85%, or 90%, or 95%, or 99%.

In some embodiments, a detergent bottle is provided, comprising a fitment welded to a detergent holding bag, the detergent holding bag having a thickness between about 0.001 inches and 0.025 inches. The detergent holding bag can be in fluid communication with a drain-back pour spout. In another embodiment, the drain-back pour spout can be integral with the fitment.

In some embodiments, a detergent bottle is provided, comprising a spout attached in fluid communication with a detergent holding bag, the detergent holding bag having a thickness between about 0.001 inches and 0.025 inches. In an embodiment, the spout includes a drain-back pour spout. In another embodiment, the spout is attached to the liquid holding bag. In another embodiment, the detergent bottle includes a fitment that can be attached to the liquid holding bag. In another embodiment, the detergent bottle includes a fitment that is integral with the spout. In another embodiment, the detergent bottle includes a fitment that is integral or unitary with the liquid holding bag.

In an embodiment, the skeleton shell can comprise any structural body that provides an enclosure and support to a liquid holding bag (or vessel). The weight of the liquid holding vessel can be supported by the skeleton. In some cases, the weight of the liquid holding vessel can be supported at a neck area only, which is connected to the skeleton. The skeleton can be formed of any material suitable for providing structural support. In some configurations, the skeleton can have sufficient structural rigidity to provide a gripping or grasping area for a user's hand and/or to prevent compression of a liquid holding vessel contained within the skeleton. The gripping or grasping area can be positioned about the liquid holding vessel, such that the liquid holding vessel is between two points on the gripping or grasping area. In such a configuration, the liquid holding vessel can exhaust its contents naturally as the liquid holding vessel collapses. A fitment, described herein, may also be designed to facilitate gripping or grasping of a container described herein. The fitment can have grooves, reinforced surfaces, or friction pads to facilitate gripping or grasping.

In an embodiment, the material used to form the skeleton can be food-grade material. In another embodiment, the materials used to form the skeleton are not food-grade materials.

In an embodiment, the material used for forming the skeleton need not be food-grade, as the liquid holding vessel can prevent contact of any liquid contained within the liquid holding vessel with the skeleton during storage of the liquid or during dispensing of the liquid. The skeleton can comprise any low embodied energy material, such as recyclable materials and/or biodegradable materials, such as molded fiber or pulp or paper. For example, the skeleton may comprise 100% post-consumer fiber or pulp feedstock. In another example, the skeleton may comprise 100% recycled corrugated fiberboard and newspaper. The skeletons or other materials described herein can include virgin pulp fiber. The skeleton can comprise type-2 molded fiber, type-2A thermoformed fiber, type-3 thermoformed fiber, type-4 thermoformed fiber, molded fiber, X-RAY formed fiber, infrared formed fiber, microwave formed fiber, vacuum formed fiber, structural fiber, sheet stock, recycled plastic or any other structural material. Any of the materials that may be used to form the skeleton may be used in any of the embodiments described herein. Any discussion of pulp may also apply to any of the materials (e.g., fiber molding, natural fibers, biodegradable or compostable materials) that may be used to form a skeleton or skeleton shell.

The skeleton can be formed from one or more sheets of material that are laminated, folded or glued together. The sheets of material can comprise hinges, joints, creases, interlocks, flanges, or flaps for simplified folding of the sheets to form the skeleton.

In some embodiments of the invention, the skeleton can comprise a fiber or pulp-molded body. The fiber and pulp-molded body can be a hollow shell, a clam shell, a two-piece shell, a multi-piece shell, or a combination thereof. The hollow shell can be a one-piece fiber or pulp-molded body where a liquid holding vessel is placed on the interior of the hollow shell through an opening of the hollow shell. The clam shell can be a fiber or pulp-molded body with a hinge that is folded around a liquid holding vessel. The hinge can be located on any side of the clam shell. For example, the hinge can be along a bottom edge or side edge of the skeleton. The clam shell and/or the liquid holding vessel can have flanges and/or interlocks for securing the clam shell to or around the liquid holding vessel. The two-piece shell can comprise two fiber or pulp-molded body pieces that can enclose a liquid holding vessel. The two pieces can have interlocks or flanges for securing the pieces to each other. The two body pieces can be separate (un-hinged) or joined (e.g., hinged). The two-piece shell can be a two-part assembly of two cup-like parts that are assembled to one another with their open ends facing one another that can enclose a liquid holding vessel. A multi-piece shell can comprise a fiber or pulp-molded body piece with a hinge or a two-piece fiber or pulp-molded body combined with a belly band and/or an end cap for securing the multi-piece shell in a closed form around a liquid holding vessel. Pieces of the skeleton can be held in place by an adhesive, a label, a mechanical deformation, or any other means known to those skilled in the arts.

The skeleton can be shaped for incorporation of functional features. In some embodiments of the invention, the skeleton can comprise openings or cut-outs. The openings or cut-outs can be located on any side or surface of the skeleton. The openings or cut-outs can provide multiple functions. These functions can include reducing the amount of material used to form the skeleton, reducing the weight of the skeleton, allowing for viewing of the contents of the container, allowing for the positioning of stiffening rib features, retaining an interlock feature from another piece of the skeleton, providing features for enhancing the ability to grasp the skeleton, providing features for separation from the liquid holding vessel, and increasing the ability to collapse or compress the skeleton. The openings or cut-outs can be formed during molding of the skeleton, or can be die-cut or water-cut after molding of the skeleton.

Reference will now be made to the figures, wherein like numerals can refer to like parts throughout. It will be appreciated that the figures are not necessarily drawn to scale.

FIG. 1 illustrates a liquid container 100, in accordance with an embodiment of the invention. The liquid container 100 includes a skeleton shell (also “skeleton” herein) 105 and a cap 110, the cap disposed on an opening of a liquid holding bag (not shown) of the liquid container 100. The skeleton shell 105 encloses the liquid holding bag. The skeleton shell 105 includes a first enclosing member 105a and a second enclosing member 105b. The first enclosing member 105a can be joined to the second enclosing member 105b. The liquid container 100 further includes one or more gripping members 115 to permit a user to hold or grip the liquid container 100. In an embodiment, the cap 110 is a measuring cap, enabling a user to measure a predetermined (or desired) volume of liquid. In another embodiment, the liquid container 100 is configured for use with a detergent.

FIG. 2 is a schematic side view of the liquid container 100 of FIG. 1, in accordance with an embodiment of the invention. The container 100 includes gripping members on each of the first and second enclosing members 105a and 105b, respectively.

FIG. 3A is a top view of a container 200 having a skeleton shell 205 in an “open” configuration, in accordance with an embodiment of the invention. The skeleton shell 205 includes a first enclosing member 205a joined to a second enclosing member 205b. The skeleton shell 205 further includes registration members 220 in a neck portion of the skeleton shell 205, the registration members 220 for mating with a fitment of spout, such as a drain-back pour spout (see below). The registration member 220 is configured to prevent the a liquid holding bag disposed in the skeleton shell 205 from rotating upon a user twisting the liquid holding bag.

FIG. 3B is a bottom view of the container 200, in accordance with an embodiment of the invention. The container 200 includes gripping members 215 for permitting a user to hold or grip the skeleton shell while in a “closed” configuration, in which case the first enclosing member 205a is disposed opposite the second enclosing member 205b.

FIG. 3C is a top view of the container 200 of FIGS. 3A and 3B, having a liquid holding bag 225 disposed in the first enclosing member 205a. The liquid holding bag 225 is sealed by a cap 210. The cap can be disposed over a spout, such as a drain-back pour spout (see below). The spout can be in fluid communication with the liquid holding bag 225. A fitment 230 disposed atop the liquid holding bag 225 can be configured to mate with the skeleton 205. The fitment 230 can include registration features for mating with registration features of each of the first and second enclosing members 205a and 205b. The fitment 230 can include one or more flanges for coming in contact with the skeleton shell 205. In an embodiment, the fitment 230 is integral with the spout.

Drain-Back Pour Spouts

In another aspect of the invention, a drain-back pour spout is provided, the drain-back pour spout configured to provide for the flow of liquid out of a liquid holding bag in fluid communication with the drain-back pour spout, and enabling fluid to drain back into the liquid holding bag. The drain-back pour spout can advantageously prevent the loss of any unused liquid, which can occur around the circumference of an opening of a container.

With reference to FIG. 4, a drain-back pour spout 300 is shown, in accordance with an embodiment of the invention. The spout 300 includes a cap 305, a pour spout 310, threads 315 for securing the cap 305 to the drain-back pour spout 300, one or more registration features 320, a bottom flange 325 and a top flange 330. In an embodiment, the cap can be a measuring cap, enabling a user to measure a predetermined or desired volume of liquid (e.g., detergent). The top flange 330 is configured to rest adjacent a top portion of a neck of a skeleton shell. In an embodiment, the top flange 330 can be attached to the top portion of the neck of the skeleton shell. In another embodiment, the bottom flange is configured to attach to a liquid holding bag (e.g., the liquid holding bag 225 of FIG. 3C).

In an embodiment, the top flange 330 can be configured to attach to or rest against a top portion of a skeleton shell, such as the top portion of a neck portion of the skeleton shell. In another embodiment, the top flange 330 can be configured to be enclosed by a top portion of a skeleton shell. In another embodiment, the bottom flange 325 can be configured to attach to or rest against a top portion of a skeleton shell, such as the top portion of a neck portion of the skeleton shell. In another embodiment, the bottom flange 325 can be configured to be enclosed by a top portion of a skeleton shell.

In an embodiment, the bottom flange 325 can be attached to a liquid holding bag. In another embodiment, the bottom flange 325 can be unitary or integral with a liquid holding bag. In another embodiment, the bottom flange 325 can be neglected, and a liquid holding bag can be attached to or integral with a bottom portion of the spout 300.

With continued reference to FIG. 4, the spout 300 can include a single registration feature 320 or a plurality of registration features angularly disposed about the spout 300. In an embodiment, the spout 300 can include a single registration feature 320. In another embodiment, the spout can include 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10 registration features, the registration features disposed about the circumference of the spout 300. In another embodiment, the spout 300 can be attached to a figment having a single registration feature 320 or a plurality of registration features angularly disposed about the fitment. In an embodiment, the spout 300 can be attached to a fitment including a single registration feature 320. In another embodiment, the spout can be attached to a fitment having 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10 registration features, the registration features disposed about the circumference of the fitment.

The registration features can be configured to mate with registration members of a skeleton shell (e.g., registration members 220 of FIG. 3A). The mating of the registration features and the registration members can prevent the spout 300 from rotating while a user rotates the cap 305. This can advantageously protect against a liquid holding bag from losing contact with the bottom flange 325.

FIG. 5 illustrates a drain-back pour spout (also “pour back spout” herein) 400 mounted on a neck portion of a skeleton shell 405, in accordance with an embodiment of the invention. The drain-back pour spout 400 includes an inner tube 401 and an outer tube 402, the outer tube 402 circumferentially enclosing the inner tube 401. The outer tube is at least partially defined by the inner tube 401. The inner tube 401, as illustrated, has a portion that is “U′ shaped. It will be appreciated, however, that the inner tube 401 can be substantially tubular. The inner tube 401 is configured to permit the flow of liquid (e.g., detergent) out of a liquid holding bag that is in fluid communication with the inner tube 401. The outer tube 402 is in fluid communication with the liquid holding bag. The outer tube 402 includes a floor portion (not shown) that is configured to capture liquid and permit the flow of liquid to the liquid holding bag. The floor portion can be in fluid communication with a fluid passageway extending from the outer tube 402 to the liquid holding bag. In an embodiment, the passageway is defined by the inner tube 401. In another embodiment, the inner tube 401 is u-shaped, and a lower portion of the u-shaped inner tube 401 is in fluid communication with the a lower portion of the outer tube 402 and an opening leading to the liquid holding bag.

FIGS. 6A and 6B show a pour back spout 500, in accordance with an embodiment of the invention. In an embodiment, the pour back spout is attached to a fitment. In another embodiment, the pour back spout is attached to the a liquid holding bag for holding or storing a liquid, such as a detergent.

FIG. 6A is a schematic side view of the pour back spout 500 with a first protrusion 505 extending beyond a second protrusion 510. FIG. 6B shows a top view of the pour back spout 500. The pour back spout 500 can include an opening 515 surrounded by the first protrusion and the second protrusion. The first protrusion and second protrusion can be connected by an apron. The second protrusion 510 of the pour back spout 500 can be connected to an upper shoulder or flange 520 that can extend orthogonally away from the second protrusion 510. A lower shoulder or flange 525 is disposed below the upper shoulder or flange 520. The upper shoulder 520 and lower shoulder 525 can be part of a fitment.

In some embodiments, a pour back spout can have an opening (or gap) 530 surrounded by a first protrusion and a second protrusion. The opening can allow fluid to pass through the spout. In some embodiments, a liquid held within a liquid holding bag can be poured out of the container through the opening in the spout. The opening 530 can be disposed in an apron of the pour back spout 505, the apron comprising a space between the first protrusion 505 and the second protrusion 510.

In some embodiments, the first and second protrusions can be arranged concentrically so that the first protrusion is at least partially surrounded by the second protrusion. In some embodiments, the first and second protrusions can be arranged so that they are not concentric, but that the first protrusion is still at least partially surrounded by the second protrusion. A gap can be provided between the first and second protrusions. In an embodiment, the gap can be defined by the first and second protrusions. The gap can be configured to capture liquid and drain the liquid back to a liquid holding bag in fluid communication with the pour back spout. In some embodiments, an apron can connect the first and second protrusions. The apron can be provided between the first and second protrusions, at a lower (or bottom) portion of the first and second protrusions. The apron can be in fluid communication with a fluid passageway back to the liquid holding bag though the opening 530.

With continued reference to FIG. 6A, the first protrusion 505 can have a rounded shape. Alternatively, the first protrusion 505 can have one or more corner or pointed portions. The first protrusion may have a cylindrical shape. In an embodiment, the first protrusion 505 can completely surround the opening 515. In another embodiment, the first protrusion 505 can partially surround the opening 515. In another embodiment, the first protrusion 505 can extend 360 degrees around the opening. In another embodiment, the first protrusion 505 can partially surround the opening 515. The first protrusion 505 can extend partway around the opening 515. In some embodiments, the first protrusion 515 can extend up to about 30 degrees, or 45 degrees, or 60 degrees, or 90 degrees, or 120 degrees, or 150 degrees, or 180 degrees, or 270 degrees around the opening 515.

In an embodiment, the first protrusion 505 can be circumferentially symmetrical about the opening 515. In another embodiment, the first protrusion 505 can extend by the same length (symmetrical) or varying lengths (asymmetrical) around the opening 515. In some embodiments, the first protrusion 505 can be contoured or curved around the opening 515.

In an embodiment, the second protrusion 510 can have a rounded shape. Alternatively, the second protrusion 510 can have one or more corner or pointed portions. The second protrusion 510 can have a cylindrical shape. In some embodiments, the second protrusion 510 can have the same shape as the first protrusion 505. Alternatively, the second protrusion 510 can have a different shape than the first protrusion 505. The cross sectional shapes of the second protrusion 510, first protrusion 505, and opening 515 can be the same or different. In some embodiments, the second protrusion 510 can completely surround the opening 515. The second protrusion 510 can extend all the way around the opening 515. In another embodiment, the second protrusion 510 can extend 360 degrees around the opening 515. In another embodiment, the second protrusion 510 can partially surround the opening 515. The second protrusion 510 can extend partway around the opening 515. In some embodiments, the first protrusion 515 can extend up to about 30 degrees, or 45 degrees, or 60 degrees, or 90 degrees, or 120 degrees, or 150 degrees, or 180 degrees, or 270 degrees around the opening 515. In an embodiment, the second protrusion 510 can include threading to accept a cap (see, e.g., FIGS. 4 and 7A).

In an embodiment, the second protrusion 510 can be circumferentially symmetrical about the opening 515. In another embodiment, the second protrusion 510 can extend by the same length (symmetrical) or varying lengths (asymmetrical) around the opening 515. In some embodiments, the second protrusion 510 can be contoured or curved around the opening 515.

The second protrusion 510 can protrude relative to a surface that the pourback (also “pour back” herein) spout 500 is affixed upon. For example, if the pourback spout 500 is connected to a fitment that is mated to a shell, the second protrusion 510 can protrude relative to the surface the shell. The second protrusion 510 protrudes relative to an apron connecting the first and second protrusions 505 and 510, respectively, and a gap can be provided between the first and second protrusions. The apron can be depressed relative to the surface of the shell. In an embodiment, the second protrusion 510 can extend at least some distance beyond the shell.

In an embodiment, the first protrusion 505 can be taller, or at the highest point protrude more than, the second protrusion 510. In an embodiment, the first protrusion 505 can be shorter or at the highest point protrude less than the second protrusion 510. Alternatively, the first protrusion 505 and the second protrusion 510 can be about the same height.

In an embodiment, the pourback spout 500 can have a vertical axis that can be perpendicular with respect to a bottom base of a container having the pourback spout 500. When the pourback spout 500 is at an upright orientation, the vertical axis can also be upright. The first protrusion 505 can be substantially parallel to the pourback spout 500. The first protrusion 505 can be parallel to the vertical axis. Alternatively, the first protrusion 505 can be angled inwards toward the center of the opening 515, outwards away from the center of the opening 515, or any combination thereof. The second protrusion 510 can be angled straight up relative to the pourback spout 500. The second protrusion 510 may be parallel to the vertical axis. Alternatively, the second protrusion 510 may be angled inwards toward the center of the opening 515, outwards away from the center of the opening 515, or any combinations thereof. The first and second protrusions 510 may be angled or not angled to the same degree relative to the vertical axis. Alternatively, they may be angled or not angled to different degrees relative to the vertical axis.

In an embodiment, the first protrusion 505 and the second protrusion 510 can be concentrically arranged so that the first protrusion 505 has a smaller cross-sectional radius than the second protrusion 510. The first and second protrusions 505 and 510 can be concentrically arranged so that the center of the cross-sectional shape defined by the first protrusion 505 is the same as the center of the cross-sectional shape defined by the second protrusion 510. In some embodiments, the first and second protrusions 505 and 510 can be almost concentrically arranged so that the center of the cross-sectional shape defined by the first protrusion 505 slightly offset from the center of the cross-sectional shape defined by the second protrusion 510. The first and second protrusions 505 and 510 need not be concentrically arranged and the center of the cross-sectional shape defined by the first protrusion 505 can be substantially offset from the center of the cross-sectional shape defined by the second protrusion 510.

In an embodiment, the second protrusion 510 may surround at least a portion of the first protrusion 505. In some embodiments, the second protrusion 510 may completely surround the first protrusion 505. The second protrusion 510 can completely encircle the first protrusion 505 and the opening 515. Alternatively, the second protrusion 510 can surround the first protrusion 505 without completely surrounding the opening 515 when the first protrusion 505 does not completely surround the opening 515. In some embodiments, the second protrusion 510 may extend around the opening 515 a larger number of degrees than the first protrusion 505. Alternatively, the second protrusion 510 can extend around the opening 515 the same or a fewer number of degrees than the first protrusion 505. In one example, the first protrusion 505 can only extend partway around the opening 515, forming a tip, and the second protrusion 510 may form a rim that completely surrounds the opening 515 and the tip.

In an embodiment, a gap can be provided between the first and second protrusions 505 and 510. The first and second protrusions 505 and 510 can be connected by an apron, that also forms the bottom of the gap. In some embodiments, the apron can be level all the way around the opening 515. For example, the apron bottom that goes around between the second protrusion 510 and the first protrusion 505 may have the same depth all the way around. Alternatively, the apron may have varying depths. For example, the apron can be slanted so that a portion of the apron is deeper than at other portions. In an embodiment, the deeper portion of the apron can be configured to direct a liquid into the opening 515 of the pourback spout 500 when the pourback spout 500 is at an upright angle. The gap between the first and second protrusions 505 and 510 may have the same dimensions all the way around the opening 515, or may vary around the opening 515. In some embodiments, a larger gap can be provided at some angles around the opening 515 of the pourback spout 500 than at other angles. The gap may have any dimensions. For example, the distance of the gap between the first protrusion 505 and second protrusion 510 can be greater than, less than, or about 3% of the diameter, 5% of the diameter, 7% of the diameter, 10% of the diameter, 12% of the diameter, or 15% of the diameter of the second protrusion 510.

In some embodiments, the first protrusion 505, second protrusion 510, and apron can be integrally formed as a single piece. The inner wall of the second protrusion 510, the outer wall of the first protrusion 505, and the apron can delineate a dip between the first and second protrusions 505 and 510. The first protrusion 505, second protrusion 510, and apron do not move relative to one another.

In some embodiments, the first protrusion 505 can be a pour tip. The pour tip can be configured to receive a liquid through the opening 515 and pour out of the container when the container and pourback spout 500 are tipped. The container and pourback spout 500 can be tipped in the direction that the pour tip is at its greatest extension from the spout. For example, if the pour tip does not extend all the way around the opening 515, the pourback spout 500 can be tipped in the direction of the pour tip. Alternatively, the pourback spout 500 can be tipped in any direction.

The second protrusion 510 can be a rim. The rim can surround the pour tip. After the liquid has been poured out of the container via the pour tip, the pourback spout 500 can be returned to a more upright orientation. The rim can capture at least some of the liquid that can run down the pour tip. The rim can be configured to reduce, minimize, or eliminate the liquid that can run down the outside of the container. The gap between the pour tip and rim can be of sufficient dimensions to capture the liquid and prevent it from flowing over the second protrusion 510. In an embodiment, the pour tip extends partially around the opening 515 so that the liquid captured by the rim can flow into the opening 530.

In alternate embodiments, additional protrusions can be provided concentrically, substantially concentrically, or not concentrically around the first and second protrusions 505 and 510. Additional protrusions can capture possible overflow of liquid.

FIGS. 7A and 7B illustrate a drainback (also “drain back” herein) spout 600, in accordance with an embodiment of the invention. FIG. 7A provides a side view of the drainback spout 600, the drainback spout 600 having a cap 610. The drainback spout 600 can have an inner pour tip 615 surrounded by an outer skirt 620. The cap 610 may be fitted over the outer skirt 620. FIG. 7B provides another side view of the drainback spout 600. The outer skirt 620 of the drainback spout 600 may be connected to an upper ridge of a fitment. A lower ridge may extend below the upper ridge. The upper ridge and lower ridge may be part of a fitment.

In an embodiment, the drainback spout 600 may have an inner pour tip 615 surrounded by an outer skirt 620. The inner pour tip 615 and outer skirt 620 may surround an opening 625 in the spout. An annular channel 630 may be provided around the inner pour tip 615 and within the outer skirt 620. The annular channel 630 may be positioned between the inner pour tip 615 and the outer skirt 620.

In some embodiments, the inner pour tip 615 may surround the opening 625 at least partway. The inner pour tip 615 may be curved and contoured to follow at least part of the shape of the opening 625. In some embodiments, the opening 625 may have a circular shape. The inner pour tip 615 may follow the circular shape. In some embodiments, the inner pour tip 615 does not extend all the way around the opening 625 so that the opening 625 may connect with the annular channel 630. In some embodiments, at least part of the bottom of the annular channel 630 may be level with or slant into the opening 625. In some embodiments, a dip or funnel may be provided that may slant downwards into the opening 625. In some embodiments, a back opening may be provided so that the annular channel 630 does not completely go around, but connects to the opening 625 at the back.

The outer skirt 620 may surround the opening 625. In some embodiments, the outer skirt 620 completely surrounds the inner pour tip 615 and the opening 625. The highest portion of the inner pour tip 615 may extend beyond the highest portion of the outer skirt 620. The outer skirt 620 may have a circular cross-sectional shape. Optionally, the outer skirt 620, inner pour tip 615, and opening 625 may be concentric. In some embodiments, the outer skirt 620 and inner pour tip 615 may be substantially parallel to one another.

The outside skirt may have an outer surface and an inner surface. The inner surface may be the surface facing the inner pour tip 615 and the opening 625 of the drainback spout 600. The opposing outer surface may face away from the inner pour tip 615 and opening 625. In some embodiments, the outer skirt 620 can have threads on outer surface. As shown in FIG. 7A, the threads on the outer skirt 620 may also enable a cap 610 to screw onto the outer skirt 620. In an embodiment, the cap is a measuring cap, enabling a user to measure a predetermined volume of liquid (e.g., detergent). In other embodiments, threads may be provided on the inner surface of the outer skirt 620. A cap 610 may optionally screw into the inner surface of the outer skirt 620. In some embodiments, the bottom of the cap 610 may fit into part of the annular channel 630 between the inner pour tip 615 and the outer skirt 620. In some embodiments, both the inner and outer surfaces of the outer skirt 620 may be threaded. In other embodiments, the outer surface of the outer skirt 620, the inner surface of the outer skirt 620, or both may have additional protrusions ridges, bumps, notches, clips, teeth, holes, or other features that may enable a cap 610 to fit on the drainback spout 600 and lock into or snap into place.

In some embodiments, the cap 610 may be formed of a transparent material. Alternatively the cap 610 may be formed of a translucent or opaque material. In an embodiment, the cap 610 may be formed of the same material as the drainback spout 600. In another embodiment, the cap 610 may be formed as the same material as a liquid holding bag in fluid communication with the drainback spout 600 (see above). The cap 610 may be formed from a polymeric material. The cap 610 may be in the same recycling group as the drainback spout 600 or the inner liner. In other embodiments, the cap 610 may be formed from a pulp-molded material. In some embodiments, the cap 610 may be formed from the same material as the shell.

In some embodiments, the cap 610 may have a substantially cylindrical sidewall. In some embodiments, the entire cylindrical sidewall may fit over the outer skirt 620 and encompass the inner pour tip 615. In some embodiments, the cap 610 may include an inner cylindrical sidewall, a shoulder and an outer cylindrical sidewall that may fit over the outer skirt 620. In some embodiments, the inner cylindrical sidewall may be provided to fit over the inner pour tip 615. Alternatively the cap 610 may be shaped to fit over the inner pour tip and between the outer skirt and the inner pour tip.

The annular channel 630 may be provided between the inner pour tip 615 and the outer skirt 620. FIG. 6B provides a top view of the annular channel (opening or gap 530, as illustrated). In some embodiments, the annular channel 630 or dip that may connect the annular channel 630 with the opening 625. A liquid may be poured from the drainback spout 600 using the inner pour tip 615. In some embodiments, after a liquid has been poured from the drainback spout 600, liquid may drain back into the opening 625 or be captured in the annular channel 630, at which point liquid can drain into the opening 625. The annular channel 630 may direct the liquid back into the opening 625 or other passages that may lead to the interior of the container, such as a liquid holding bag in fluid communication with the opening 625.

FIG. 8A shows a top angled view of a drain back pour spout 700, in accordance with an embodiment of the invention. The drain back pour spout 700 may have an opening 705 in fluid communication with a liquid holding bag (now shown; see above). The drain back pour spout 700 may have an inner lip 710 and an outer sidewall 715 that surround the opening 705. A capture conduit 720 can surround the inner lip 710 and may be surrounded by the outer sidewall 715. A drainage passage 725 may be provided in the capture conduit 720. In some cases, the capture conduit 720 is a trough. FIG. 8B provides a lower angled view of a drain back pour spout 700. The drainage passage 725 may provide a fluidic connection between the capture conduit 700 and the interior of the container, such as a liquid holding bat (see above).

In some embodiments, the inner lip 710 may completely surround the opening 705. A portion of the inner lip 710 may extend higher than another portion of the inner lip 710. In some embodiments, about three quarters, two thirds, or one half of the inner lip 710 may extend higher than the other portion of the inner lip 710. In some embodiments, the taller portion of the inner lip 710 may extend taller than the outer sidewall 715 while the shorter portion of the inner lip 710 does not. In some embodiments, the transition between the taller and shorter portions of the inner lip 710 may contoured so that the exposed edges of the inner lip 710 are curved. The outer sidewall 715 may have the same or approximately the same height all the way around.

With continued reference to FIGS. 8A and 8B, In an embodiment, the capture conduit 720 may be provided between the inner lip 710 and the outer sidewall 715. The capture conduit 720 may be provided lower than the inner lip 710 and the outer sidewall 715. The capture conduit 720 may be formed between the inner surface of the outer sidewall 715 and the outer surface of the inner lip 710. In some embodiments, the capture conduit 720 may form a circular or elliptical shape around the inner lip 710. The capture conduit 720 may include a floor that may connect the inner lip 710 and outer sidewall 715. In some embodiments, the floor and capture conduit 720 may form a ring-like shape. In some embodiments, the floor may form an uninterrupted annular shape, while in other embodiments, one or more drainage passageways may be provided in the floor of the capture conduit 720.

In an embodiment, a drainage passage 725 may be provided in the capture conduit 720. In some embodiments, only one drainage passage 725 may be provided. Alternatively, a plurality of drainage passages 725 (e.g., 2, 3, 4, 5, 6, or more) may be provided. The drainage passages 725 may be holes, vents, openings 705, cracks, tubes, or any other passageway that may fluidically connect the capture conduit 720 and the interior of a container in fluid communication with the drain back pour spout 700. The drainage passage 725 may allow a liquid captured within the capture conduit 720 to drain into the container. In some embodiments, the drainage passage 725 may direct the capture liquid into the opening 705. Alternatively, the drainage passage 725 may separately drain the liquid into the container. The drainage passage 725 may be provided at the floor of the capture conduit 720. In some embodiments, the drainage passage 725 may include part of the inner lip 710 or the outer side wall.

In some embodiments, the drainage passage 725 may be located in the capture conduit 720 on the side furthest from the tallest portion of the inner lip 710. For example, the drainage passage 725 can be located at the side of the drain back pour spout 700 closer to the shorter portion of the inner lip 710. Positioning the drainage passage 725 away from the tallest portion of the inner lip 710 may prevent or reduce liquid from flowing out of the container into the capture conduit 720 when the liquid is being poured out of the container. After liquid has been poured from the container, and container is returned to an upright position, some of the liquid may be captured within the capture conduit 720, and may flow through the drainage passage 725 into the interior of the container.

With reference to FIGS. 9A and 9B, a drain-back pour spout 800 is shown having registration members 805. The registration members 805 can be configured to mate with registration features on a skeleton shell (see above). In some embodiments, the registration members 805 can be for locking the drain-back pour spout 800 to a skeleton shell, such as a neck region of the skeleton shell (also “shell” herein). In an embodiment, the registration members 805 are formed to complement an inner surface of the skeleton shell. In another embodiment, the registration members 805 can be configured to lock the spout 800 to prevent or minimize rotational movement, vertical movement (i.e., movement along an axis orthogonal to a base of a container having the spout 800), or horizontal movement (i.e., movement along an axis parallel to a base of a container having the spout 800). In an embodiment, the registration members are configured to reduce or eliminate the rotation of the drain-back pour spout 800 when it has been enclosed by a skeleton shell, such rotation coming by way of a user rotating a cap of the drain-back pour spout 800, for example. In an embodiment, the drain-back pour spout 800 can include 1, or 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10 registration members. The registration members 805 can have any shape, size and configuration. The registration members 805, as illustrated, have an elongate, rectangular shape, with a horizontal cross-beam. In an embodiment, the registration members 805 can be formed of ridges. In another embodiment, the registration members 805 can be formed of notches (e.g., metallic notches, polymer notches). In another embodiment, the registration members 805 can be formed of grooves. In another embodiment, the registration members 805 can be formed of one or more of notches, ridges and grooves. In another embodiment, the registration members 805 can be formed of a magnetic material or a locking mechanism. In another embodiment, the registration members 805 can be formed of one or more hook-and-loop fasteners. In another embodiment, the registration members 805 can include one or more metal hooks.

In an embodiment, the registration members 805 can be circular or have circular cross sections. In another embodiment, the registration members 805 can be triangular. In another embodiment, the registration members 805 can be box-like. In another embodiment, the registration members 805 can be rectangular. In another embodiment, the registration members 805 can be pentagonal. In another embodiment, the registration members 805 can be hexagonal. In another embodiment, the registration members 805 can be heptagonal. In another embodiment, the registration members 805 can be octagonal. In another embodiment, the registration members 805 can be formed of 1, or 2, or 3, or 4, or 5, or 6, or 7, or 8, or 9, or 10 cross beams. In another embodiment, the registration members 805 can be “H” shaped (as illustrated).

In another aspect of the invention, a method for assembling a liquid holding container is provided, the method comprising enclosing a liquid holding bag in a low embodied energy skeleton shell, the liquid holding bag comprising a drain-back pour spout. In an embodiment, the liquid holding bag can have a thickness between about 0.001 inches and 0.025 inches. In another embodiment, the drain-back pour spout is disposed at a top portion of the liquid holding bag.

In an embodiment, containers are able to me made on high-speed production lines and high speed filling line in order reduce costs and be competitive with other aforementioned packaging technologies. In some embodiments, containers or bottles can be fully assembled prior to filling. The pouches could be made on a horizontal forming machine with or without fitment inserter. The pouches could be made on other known machines. They are then assembled into the skeleton shell. Either the pouch or the shell, or both could have one or more features to facilitate automated assembly. The skeleton shell and pouch with fitment are then assembled. A standard bottling line can be used where the container fills similarly to a standard bottle. In such a case, various components provided herein, such as skeletons and liquid holding bags, can be integrated into existing standard bottling lines, thereby making use of exiting infrastructures. In other embodiments, the pouch and fitment can run and be filled on either Horizontal Form Fill machines or Vertical Form Fill machines. These filled pouches can then be assembled to skeleton shells to complete the product containers.

Containers provided herein can be designed to minimize materials cost, thus aiding in the reduction of post-use waste. In addition, materials can be selected so as to minimize environmental impact. For example, the skeleton can be formed of a biodegradable material.

In some embodiments, containers can be permanent containers. In some embodiments, containers can be designed to mate various components, such as caps and pouches. In some cases, containers can be designed to mate with smart caps and pouches. In various embodiments, containers can be configured for use with turn-key integrated manufacturing equipment.

Filling Containers

In various embodiments, methods for filling containers having liquid holding bags within skeleton shells are provided. In an embodiment, containers are filled with a detergent. In an embodiment, there is space between a skeleton and a liquid holding bag within the skeleton so that air (or another gas) within the skeleton (or shell) can be displaced through the shell as the liquid holding bag is filled. In addition, air can pass through the skeleton to fill the volume as contents are dispensed from the bag. Allowing air to pass into the volume inside the skeleton as the contents are dispensed from the liquid holding bag helps with the smooth dispensing of the contents of the liquid holding bag. In an embodiment, the flow of air through the skeleton can be achieved using the porosity of the skeleton. In another embodiment, the flow of air through the skeleton can be achieved with the aid of a vent in the skeleton. In such a case, the vent can be provided at a position where there is little risk of puncturing the liquid holding bag.

In an embodiment, a container, such as the container 200 of FIG. 3C, can be filled by introducing content, such as liquid content, through a closure of the container and into a liquid holding bag of the container. The closure can be a sealable or re-sealable closure. In an embodiment, as the liquid holding tank is filled with the contents of the container, gas, such as air, is displaced.

In an embodiment, before filling, the liquid holding bag within the skeleton can be rolled to assist with the laying of the liquid holding bag within the skeleton. In this case, the liquid holding bag can be folded or rolled in such a way that it can easily unfold or unroll, such as, for example when the liquid holding bag is filled. Any folds or rolls may be lightly held by one or more holding members, such as, e.g., thin pieces of tape that will release as the bag fills. Alternatively, the bag can be held in the folded or rolled condition by an adhesive, clip or band. During filling, as the body of the liquid holding bag expands, such as, for example, by injecting a gas into the bag prior to filling or expansion of the liquid holding bag upon filling the bag with its contents, the retaining means can be ruptured or removed from the liquid holding bag to allow the body of the liquid holding bag to expand. By folding or rolling the liquid holding bag prior to laying it into the skeleton of the container, various issues, such as, for example, the liquid holding bag getting caught by the skeleton when enclosing the liquid holding bag, can be minimized. This filling procedure further helps the liquid holding bag fill properly, as it will assume the correct internal orientation when filled.

In an embodiment, the liquid holding bag has a volume greater than the internal volume of the skeleton. In this way, when the liquid holding bag of the container is filled, the liquid holding bag will come in contact the inner surface of the skeleton. This can help ensure that the weight of the contents is supported by the skeleton rather than by the liquid holding bag.

In some cases, the closure of a liquid holding bag includes the pour spout (e.g., drain-back pour spout) of the liquid holding bag.

In some embodiments, after filling, the openings through which content is introduced to the liquid holdings, such as the closures of the liquid holding bags, are sealed. In an embodiment, the closures can be sealably or re-sealably closed with a sealing member, such as a cap (e.g., smart cap), twist cap, snap cap, or lid. The closures can be sealed in a controlled environment, such as an inert environment or under vacuum, or in the ambient environment.

In some embodiments, the openings through which content is introduced to the liquid holding bags is sealed with the aid of a removable sealing member having a gripping member for enabling a user to remove the seal. In some cases, the opening of a closure is sealed with a sealing member and further sealed with a cap. A user removes the cap and removes the sealing member to expose the opening of the closure.

A sealing member can be reversibly removable. That is, a user can remove the sealing member to expose the opening of the closure and replace the sealing member to reseal the opening.

FIGS. 10A-10D schematically illustrate a pour spout 1000 having a removable sealing member 1005, in accordance with an embodiment of the invention. The pour spout 1000 can be mounted to holding bags, fitments and shells provided herein. The pour spout 1000 can be a drain-back pour spout, configured to, for example, capture spillover material from the container. The pour spout 1000 is configured for use with containers and liquid holding bags provided herein. With reference to FIGS. 10A and 10B, the removable sealing member 1005 includes a gripping member 1010 for enabling a user to remove the removable sealing member 1005 from the pour spout 1000. The gripping member 1010 is a tab (or projection), but gripping members with other shapes, sizes and configurations are possible. With reference to FIG. 10C, the removable sealing member 1005 includes an arrow 1015 for instructing a user as to the direction to pull the gripping member 1010. For example, to remove the removable sealing member 1005, the user can grip the gripping member 1010 and force it (e.g., push or pull) in the direction of the arrow 1015. With reference to FIG. 10D, the pour spout 1000 includes a capture conduit 1020 to capture content from a container in fluid communication with the pour spout 1000. In some cases, the capture conduit 1020 is a trough that captures excess content (e.g., spillover).

With reference to FIGS. 11A-11D, the removable sealing member 1005 can be removed from the pour spout 1000 to expose an opening 1025 (see FIGS. 11C and 11D) of the pour spout 1000. The opening 1025 can permit a user to dispense the content of a container having the pour spout 1000. The pour spout 1000 includes a drainage passage 1030 (see FIG. 11A) that is in fluid communication with a liquid holding bag of a container (not shown) having the pour spout 1000.

The opening 1025 can have various shapes and sizes. In some embodiments, the opening 1025 has a cross-section that is in whole or in part circular, triangular, square, rectangular, pentagonal, hexagonal, heptagonal, or octagonal.

The opening 1025 is defined by a wall having a rim 1025a. The pour spout 1000 includes a side opening 1035 extending from the rim 1025a to a base of the capture conduit 1020. The side opening 1035 terminates at the drainage passage 1030. The opening 1025 and the side opening 1035 are sealed with the removable sealing member 1005. Removal of the removable sealing member 1005 exposes the opening 1025 and the side opening 1035. In another embodiment, the sealing member 1005 is only partially removed, which can be sufficient to allow the contents of the container to be dispensed while still remaining partially joined to the spout 1000. The sealing member 1005 can then be used to re-seal the container. In some cases it can be returned to its original position for re-use.

In some embodiments, the side opening 1035 of the pour spout 1000 can be precluded and the pour spout 1000 can include only the opening 1025. The pour spout 1000 can include the drainage passage 1030 for directing material to a liquid holding bag in fluid communication with the spout 1000. The removable sealing member 1005 in such a case can be shaped to cover the opening 1025. For example, the opening 1025 can be circular and the removable sealing member 1005 can be circular. A user can remove the removable sealing member 1005 by pulling on the tab 1010.

In some embodiments, the removable sealing member 1005 is disposable. The removable sealing member 1005 can be formed of a recyclable and/or biodegradable material, such as a polymeric material or vegetable material.

In an example, a container is provided having the pour spout 1000. A user removes the removable sealing member 1005 by pulling on the gripping member 1010 to expose an opening of the pour spout 1000. The user inverts the container to remove a certain quantity of material in the container, and subsequently turns the container upright. Some of the material from the container spills into the capture conduit 1020 and is subsequently returned to the container via the drainage passage 1030.

The removable sealing member 1005 can provide various uses. In some situations, the removable sealing member 1005 can enable vertical (e.g., a container aligned with the gravitational acceleration vector) filling and sealing of a container having a spout with the removable sealing member 1005. In an example, a container is filled vertically and subsequently sealed with the removable sealing member. In some cases, the container can be molded closed. This can aid in minimizing, if not preventing, leaking during container filling and sealing.

In an example, a spout, such as the spout 1000, can be attached to a pouch (or material holding vessel). The spout can be sealed to the pouch. The pouch can then be filled in a vertical fashion. In some cases an opening of the spout can be sealed with the aid of a sealing member, such as the sealing member 1005. The pouch may be vacuum sealed, or sealed in an inert (or other controlled) environment. The spout can then be enclosed within a cap. In some situations, the sealing member can be precluded and the spout can be sealed with the aid of the cap.

Containers can benefit from certain features to help their merchandizing. These could include an ability to suspend the product at point of sale. This could include features to allow for the suspension on rails of the recharge pouches. Recharge pouches, or refill pouches, could be sold as single items or as groups of pouches, and are swappable into a skeleton shell after another one has been emptied. For example, a single pouch can be purchased and inserted into the skeleton shell of another container after the removal of the skeleton shell of that container. A number of pouches could be sold with a single skeleton shell. The skeleton shell could be intended to be recycled after a number of uses or intended to be used indefinitely. The recharge pouches could have a limited amount of packaging attached at retail points for branding purposes or merchandizing purposes. This limited packing could also serve a function in the reconnection to the skeleton shell, its subsequent use, or intended for removal and recycling. This new packaging invention could have features for merchandizing or meeting logistical needs.

For other contents that may not be dependent on fitments, a flexible pouch mated to a biomaterial based thermoformed skeleton, with the option of using recycled content in the format of a bowl/cup/tray, could be used. Separable components for recycling can be used in certain cases. There would be a removable tamper evident seal. The liner would be separable from the bowl/cup/tray. This could be for refrigerated or frozen items, such as, e.g., yogurt, ice cream, ready-to eat-meals, salads, dried fruit, olives, and margarine. Such containers can be used with non-refrigerated items (e.g., nuts, spices), and they could be resealable with the aid of, e.g., lids or re-stackable peel away tabs. In an embodiment, such containers can include a separable liner and skeleton technology for items that are in jars or cans (structured) or in stand up pouches. Items that could benefit from such containers include items that could benefit from more structure but less plastic, such as, e.g., nuts, dried fruits, and snacks.

While in various embodiments containers have been described as being configured for storing and dispensing liquids, it will be appreciated that containers of provided herein can be for storing and dispensing non-liquids, gels, gel-like materials, solids, such as edible or inedible solids, including powders.

Containers provided herein can be joined at one or more base members. In an example, a container can include a skeleton shell having a tri-fold design (i.e., opposing side members joined at a base member).

One or more components, parts, features, or characteristics of liquid containers, liquid holding bags and/or spouts known in the art can be used with or incorporated into containers, holding bags and/or spouts provided herein. See, e.g., U.S. Pat. No. 7,686,188, U.S. Pat. No. 7,721,916, U.S. Pat. No. 6,968,980, U.S. Pat. No. 6,464,106, U.S. Pat. No. 6,431,401, U.S. Pat. No. 6,398,076, U.S. Pat. No. 6,375,041, U.S. Pat. No. 6,279,789, U.S. Pat. No. 6,223,945, U.S. Pat. No. 6,223,946, U.S. Pat. No. 6,209,762, U.S. Pat. No. 6,123,231, U.S. Pat. No. 6,032,829, U.S. Pat. No. 5,941,422, U.S. Pat. No. 5,855,299, U.S. Pat. No. 5,794,803, U.S. Pat. No. 5,603,787, U.S. Pat. No. 5,597,090, U.S. Pat. No. 5,566,862, U.S. Pat. No. 5,431,306, U.S. Pat. No. 5,251,788, U.S. Pat. No. 5,234,130, U.S. Pat. No. 5,207,356, U.S. Pat. No. 5,131,566, U.S. Pat. No. 5,114,659, U.S. Pat. No. 5,108,009, U.S. Pat. No. 5,058,772, U.S. Pat. No. 4,993,605, U.S. Pat. No. 4,984,714, U.S. Pat. No, 4,981,239, U.S. Pat. No. 4,974,749, U.S. Pat. No. 4,917,270, U.S. Pat. No. 4,917,269, U.S. Pat. No. 4,917,268, U.S. Pat. No. 4,890,770, U.S. Pat. No. 4,863,067, U.S. Pat. No. 4,836,419, U.S. Pat. No. 4,830,234, U.S. Pat. No. 4,773,560, U.S. Pat. No. 4,706,829, U.S. Pat. No. 4,696,416, U.S. Pat. No. 4,671,421, U.S. Pat. No. 7,686,188 (“DRAIN-BACK SPOUT FITMENT CLOSURE WITH DRIP-LESS POUR TIP”) and U.S. Patent Publication No. 2011/0220652 (“CONTAINERS FOR HOLDING MATERIALS”), which are entirely incorporated herein by reference. For example, fitments, collars and shells of U.S. Patent Publication No. 2011/0220652 may be used with pour spouts provided herein.

It should be understood from the foregoing that, while particular implementations have been illustrated and described, various modifications can be made thereto and are contemplated herein. It is also not intended that the invention be limited by the specific examples provided within the specification. While the invention has been described with reference to the aforementioned specification, the descriptions and illustrations of the preferable embodiments herein are not meant to be construed in a limiting sense. Furthermore, it shall be understood that all aspects of the invention are not limited to the specific depictions, configurations or relative proportions set forth herein which depend upon a variety of conditions and variables. Various modifications in form and detail of the embodiments of the invention will be apparent to a person skilled in the art. It is therefore contemplated that the invention shall also cover any such modifications, variations and equivalents.

Claims

1. A liquid container, comprising:

a liquid holding bag;

a drain-back pour spout in fluid communication with the liquid holding bag; and

a skeleton shell for supporting the liquid holding bag, the skeleton shell formed of a molded fiber or pulp-formed material.

2. The liquid container of claim 1, wherein the skeleton shell comprises a first side member and second side member.

3. The liquid container of claim 1, wherein the drain-back pour spout is formed from a polymeric material.

4. The liquid container of claim 1, wherein the drain-back pour spout is disposed at a top portion of the liquid holding bag.

5. The liquid container of claim 1, wherein the liquid holding bag is formed from a polymeric material.

6. The liquid container of claim 1, wherein the liquid container has a thickness between about 0.001 inches and 0.025 inches.

7. The liquid container of claim 1, wherein the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.

8. A low embodied energy liquid container, comprising:

a liquid holding bag;

a drain-back pour spout in fluid communication with the liquid holding bag; and

a skeleton shell for supporting the liquid holding bag, the skeleton shell formed from a low embodied energy material.

9. The low embodied energy container of claim 8, wherein the low embodied energy material comprises molded fiber or a pulp-formed material.

10. The low embodied energy container of claim 8, wherein the low embodied energy material comprises 25-100% pulp by weight of the skeleton shell.

11. The low embodied energy container of claim 8, wherein the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.

12. A detergent bottle comprising a fitment welded to a detergent holding bag, the detergent holding bag having a thickness between about 0.001 inches and 0.025 inches.

13. A detergent bottle comprising a spout attached to a detergent holding bag, the detergent holding bag having a thickness between about 0.001 inches and 0.025 inches.

14. The detergent bottle of claim 13, wherein the spout comprises a removable sealing member at an opening of the drain-back pour spout.

15. A method for assembling a liquid holding container, comprising:

enclosing a liquid holding bag in a low embodied energy skeleton shell, the liquid holding bag comprising a drain-back pour spout.

16. The method of claim 15, wherein the liquid holding bag has a thickness between about 0.001 inches and 0.025 inches.

17. The method of claim 15, wherein the drain-back pour spout is disposed at a top portion of the liquid holding bag.

18. The method of claim 15, wherein the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.

19. A container, comprising:

a pour spout; and

a skeleton shell attached to the pour spout, the skeleton shell formed of a low embodied energy material.

20. The container of claim 19, wherein the low embodied energy material comprises molded fiber or a pulp-formed material.

21. The container of claim 19, wherein the pour spout includes a drain-back pour spout.

22. The container of claim 19, wherein the pour spout includes registration members for locking the pour spout to one or more surfaces of the pour spout.

23. The container of claim 19, wherein the pour spout is for dispensing an edible or inedible liquid.

24. The container of claim 19, wherein the pour spout is for dispensing an edible or inedible solid.

25. The container of claim 19, further comprising a fitment for attachment to the skeleton shell.

26. The container of claim 19, wherein the pour spout comprises a removable sealing member at an opening of the pour spout.

27. A container, comprising:

a skeleton shell formed of a molded fiber or pulp-formed material; and

a drain-back pour spout at an opening of the skeleton shell.

28. The container of claim 27, wherein the drain-back pour spout comprises a removable sealing member at an opening of the drain-back pour spout.