[0001]This application claims the benefit of and/or priority from United States Provisional Patent Application No. 62/758,719 filed on November 12, 2018, which is incorporated herein by reference in its entirety.

FIELD

[0002] This document relates to containers. More specifically, this document relates to containers such as coffee cups, drinking bottles, containers for household supplies, as well as related sets and methods.

BACKGROUND

[0003] United States Patent No. 10, 189,604 B2 (McMunn) discloses a container that includes a plant based structural layer having an inner surface and an opposed outer surface, and a pre-formed polymeric liner layer secured to the plant based structural layer and lining at least one of the inner surface and the outer surface.

SUMMARY

[0004] The following summary is intended to introduce the reader to the subject matter of the detailed description, and does not define or delimit any invention.

[0005] According to some aspects, a container includes a plant based structural layer having an inner surface and an opposed outer surface and including a first panel and a second panel. The first panel and the second panel each have a respective pair of opposed side edges. The first panel and the second panel are joined to each other along the side edges. The container is movable between a flattened configuration in which the panels are flattened to provide a flattened container, and an expanded configuration in which the panels are expanded outwardly to define an interior volume of the container therebetween. A pre-formed polymeric liner layer is secured to the plant based structural layer and lines the inner surface. When the container is in the flattened configuration, the pre-formed polymeric liner is crushed between the first panel and the second panel, and when the container is in the expanded configuration, the pre-formed polymeric liner is expanded. An end cap is joined to the first panel by a flexible hinge, and joined to the second panel by a foldable tab. When the container is in the flattened configuration, the foldable tab is folded and the end cap is generally parallel to the first panel and the second panel and lies generally flat between the first panel and the second panel. When the container is in the expanded configuration, the foldable tab is unfolded and the end cap is perpendicular to the first panel and second panel.

[0006] In some examples, the tab includes a first adhesive-coated region, and the second panel includes a second adhesive-coated region. When the container is in the expanded configuration, the first adhesive-coated region contacts the second adhesive-coated region. The first adhesive-coated region and the second adhesive-coated region can include a self-adhesive.

[0007] In some examples, the structural layer includes a first sub-layer that includes the inner surface and a second sub-layer that includes the outer surface. The first sub-layer can be coarse-grained, and the second sub-layer can be fine-grained. A third sub-layer can be between the first sub-layer and second sub-layer, and the third sub-layer can be an insulation layer.

[0008] In some examples, the container includes a base portion and a neck portion that is narrower than the base portion. The neck portion can be configured to receive a lid of the container.

[0009] According to some aspects, a set of containers includes a first container and a second container. Each of the first container and the second container is in a flattened configuration, and is movable to an expanded configuration. The first container and the second container are separably joined together to form a flattened package.

[0010] In some examples, the flattened package is a flattened rectangular package.

[0011] In some examples, the first container and the second container house a product precursor, and the first container and the second container are sealed shut. [0012] In some examples, each container includes a base portion and a neck portion that is narrower than the base portion. The neck portion can be configured to receive a lid of the container. The neck portion of the first container can be nested against the base portion of the second container, and the neck portion of the second container can be nested against the base portion of the first container.

[0013] In some examples, the first container and second container are joined together with an adhesive tape.

[0014] In some examples, each of the first container and the second container includes a respective plant based structural layer having an inner surface and an opposed outer surface, and a respective pre-formed polymeric liner layer secured to the plant based structural layer and lining the inner surface. Each structural layer can have a first panel and a second panel, the first panel and the second panel can each have a respective pair of opposed side edges, and the first panel and the second panel can be joined to each other along the side edges.

[0015] According to some aspects, a method for providing a product includes: a. joining together a first container in a flattened configuration and a second container in a flattened configuration to form a flattened package; b. shipping the flattened package to an end- location; c. at the end location, separating the first container and the second container; d. configuring the first container and the second container to an expanded configuration; and e. filling the first container and the second container.

[0016] In some examples, the method further includes, prior to step b., affixing a mailing label directly to the rectangular package.

[0017] In some examples, the method further includes, prior to step b., loading the first container and the second container with a respective product precursor.

[0018] In some examples, the method further includes sealing the respective product precursors within the first container and the second container. [0019] In some examples, the method further includes securing a first lid to the first container and a second lid to the second container.

[0020] In some examples, step e. includes re-constituting a concentrate.

[0021] In some examples, step a. includes securing the first container and the second container together using an adhesive tape.

[0022] According to some aspects, method for providing a product includes a. providing a container that includes a plant based structural layer having an inner surface and an opposed outer surface, and a polymeric liner layer secured to the plant based structural layer and lining the inner surface, wherein the container is movable between a flattened configuration and an expanded configuration; b. expanding the container from the flattened configuration to the expanded configuration; c. loading the container; and d. dispensing the container.

[0023] In some examples, steps b. to d. are carried out by a vending machine.

[0024] In some examples, step a. includes providing a product-precursor within the container, and step c. comprises reconstituting the product precursor.

[0025] In some examples, step c. comprises loading the container with a product precursor. In some examples, step d. comprises shipping the container.

[0026] In some examples, steps b. to d. are carried out on demand.

[0027] In some examples, the method further includes printing on the container.

BRIEF DESCRIPTION OF THE DRAWINGS:

[0028] Figure 1 is a perspective view of a structural layer of a“ships-flat container” in the form of a cup, when in the flattened configuration;

[0029] Figure 2 is a cross-section taken along line 2-2 in Figure 1 , and also showing a polymeric liner layer; [0030] Figure 3 is a top view of the side panels of the structural layer of Figure 1 ;

[0031] Figure 4 is a cross-section similar to that of Figure 2, but showing the cup in the expanded configuration;

[0032] Figure 5 is a top view similar to that of Figure 2, but showing the cup in the expanded configuration;

[0033] Figure 6 is a schematic view of a machine for printing on containers;

[0034] Figure 7 is a schematic view of a machine for printing on containers and then filling and expanding and sealing the containers;

[0035] Figure 8 is a schematic view showing a series of steps for expanding cups;

[0036] Figure 9A is a plan view of another“ships-flat container” in the form of a bottle, when in the flattened configuration;

[0037] Figure 9B is a side view of the bottle of Figure 9A;

[0038] Figure 10A is a perspective view of the bottle of Figure 9A, when in the expanded configuration, and also showing a lid;

[0039] Figure 10B is a side view of the bottle of Figure 10A;

[0040] Figure 11 is a cutaway view of the bottle of Figures 9A to 10B;

[0041] Figure 12 is a bottom view of a flattened rectangular package including two of the bottles of Figures 9A to 10B;

[0042] Figure 13 is a top view of the flattened rectangular package of Figure 12;

[0043] Figure 14 is a rear view of the flattened rectangular package of Figure 12, being placed into an envelope;

[0044] Figure 15 is a perspective view of another example container; and [0045] Figure 16 is an exploded view of another example container.

DETAILED DESCRIPTION

[0046]Various apparatuses or processes or compositions will be described below to provide an example of an embodiment of the claimed subject matter. No embodiment described below limits any claim and any claim may cover processes or apparatuses or compositions that differ from those described below. The claims are not limited to apparatuses or processes or compositions having all of the features of any one apparatus or process or composition described below or to features common to multiple or all of the apparatuses or processes or compositions described below. It is possible that an apparatus or process or composition described below is not an embodiment of any exclusive right granted by issuance of this patent application. Any subject matter described below and for which an exclusive right is not granted by issuance of this patent application may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors or owners do not intend to abandon, disclaim or dedicate to the public any such subject matter by its disclosure in this document.

[0047] The inventor’s previous patent (United States Patent No. 10, 189,604 B2 to McMunn, which is incorporated herein by reference in its entirety) discloses a container (e.g. a cup or a bottle) that includes a plant based structural layer (e.g. bagasse) and a pre-formed polymeric liner (e.g. a silicone liner) secured to the plant based structural layer and lining the inner surface and/or the outer surface of the structural layer. The container can be a“ships-flat container” - i.e. can be configured to be shipped and stored in a generally flat configuration. For example, the structural layer can include a pair of flexible panels. Each panel can have a pair of opposed side edges, and the pair of panels can be joined to each other along the side edges. The container can be reconfigurable between a flattened configuration in which the panels are flattened to provide a substantially flattened container, and an expanded configuration in which the panels are flexed outwardly to define an interior volume of the container therebetween. [0048] Disclosed herein are additional and/or alternative configurations of such“ships-flat containers”, as well as processes and systems for preparing such“ships-flat containers” for use - i.e. for printing on the containers prior to reconfiguring the containers from the flattened configuration to the expanded configuration, and/or for reconfiguring the containers from the flattened configuration to the expanded configuration, and/or for filling and sealing the containers. Also disclosed herein are“form-on-demand” containers.

[0049] Referring to Figures 1 to 5, an example of a“ships-flat container” and“form-on- demand” container is shown. In the example shown, the container is in the form of a cup 100. In Figures 1 to 3, the cup 100 is (or parts thereof are) shown in a flattened configuration, and in Figures 4 and 5, the cup 100 is (or parts thereof are) shown in an expanded configuration. In Figures 1 to 3, the cup is not shown as being entirely flat, so that the parts of the cup are more visible. Furthermore, the terms“flat” and“flattened” as used herein are used in the relative sense with regard to the term ’’expanded”, and containers described herein as being“flat” or“flattened” may not be entirely flat. The cup 100 includes a plant-based structural layer 102 (further details of which are described in detail in US 10, 189,604 B2), which includes a pair of flexible side panels 104, 106 (also referred to herein as a‘first side panel 104’ and a‘second side panel 106’) that are joined together along their side edges (seen most clearly in Figure 3), and an end cap 108 (which is between the panels 104, 106 and is shown in dotted line in Figure 1 ) that is joined to one of the side panels 104 by a flexible hinge 1 10 and to the other of the side panels 106 by a tab 1 12 that is folded along a fold line 1 14. A pre-formed polymeric liner 1 16 (shown only in Figure 2, and further details of which are described in detail in US 10, 189,604 B2) is secured to the structural layer 102 and lines the inner surface of the structural layer 102. When the cup 100 is in the flattened configuration, the panels 104, 106 lie generally flat against each other, the cap 108 is generally parallel to the side panels 104, 106 and lies generally flat between the side panels 104, 106, and the liner 1 16 is crushed between the panels, 104, 106.

[0050] The panels 104, 106 can optionally be separate pieces that are, for example, glued together along their side edges, or joined together along their side edges by an intermediate piece (e.g. a pleated piece), or can be one piece that is folded to create the side edges. The end cap 108, hinge 1 10, and tab 1 12 can optionally be separate pieces that are glued together and to the side panels 104, 106, or one-piece that is glued to the side panels 104, 106.

[0051] The liner 1 16 can optionally be glued to the side panels 104, 106 or secured to the side panels 104, 106 in another manner, e.g. as described in US 10, 189,604 B2.

[0052] Referring to Figure 2, an adhesive may be applied to a region 1 18 (also referred to as a‘first adhesive coated region 1 18’) of the tab 1 12, and to a region 120 (also referred to as a‘second adhesive coated region 120’) of the side panel 106. The adhesive may be of the type that adheres only to itself (i.e. a self-adhesive compound), so that when the cup 100 is in the flattened configuration, the adhesive is not activated to adhere to anything.

[0053] Referring to Figures 4 and 5, upon expansion to the expanded configuration, the end cap 108 pivots downwardly about the hinge 1 10 and the tab 1 12 unfolds, and the side panels 104, 106 flex outwardly (seen most clearly in Figure 5), to define an interior volume of the container therebetween. The tab 1 12 is sized so that when it is completely unfolded, the end cap 108 is perpendicular to the side panels 104, 106. When the tab 1 12 is completely unfolded, the adhesive region 1 18 of the tab 1 12 contacts the adhesive region 120 of the side panel 106, to adhere the tab 1 12 to the side panel 106 and hold the cup 100 in the expanded configuration.

[0054] In use, the cups 100 may be shipped and stored in the flattened configuration, and may be expanded when ready for use. In some examples (not shown), the cups 100 can be expanded in an automated process. For example, the cups 100 can be stored flat in a hopper. When ready for use, a cup 100 can be placed into a tube. Air or another gas can be blown through the tube, in a direction going from the top end of the cup 100 to the bottom end. The flow of air can force the liner 1 16 to expand, force the end cap 108 to pivot downwardly about the hinge 1 10, and force the panels 104, 106 to flex outwardly. Optionally, the flow of air can also seal a lid onto the cup 100. Alternatively, a cup 100 can be squeezed so that the side edges are pressed inwardly, to expand the cup. An example of a machine that operates to expand the cups by squeezing is shown in Figure 8. In Figure 8, a pair of actuators 800 come together to squeeze the cup 100 and cause the panels 104, 106 to flex outwardly towards the expanded configuration. The machine can also apply a vacuum, which can cause the liner 1 16 to expand and cause the end cap 108 to move downwardly (not shown in Figure 8). Optionally, the cup 100 can sit in the machine so that the top protrudes slightly, allowing a lid to be placed on the cup 100.

[0055] In alternative examples, mechanical devices such as tampers, crimpers, calliper type devices, pulling/pushing armatures can be used to facilitate expansion of the containers. In some examples, a supplementary jig can be employed, for instance on the top lip of the container that protrudes above the top edge of the expanding jig. Once the lid has been placed onto the container and covers the protruding lip of the container, a jig, which matches the shape and height of the protruding lip (now covered by a downward flange of the lid), can move into position to brace this area, so that when compressed air or gas or liquids are forced into the container to fully seat mechanical connections or to cause the full contact of adhesives, the pressure does not push this area out of shape or burst through the walls of the container or deform or stretch or rupture the polymeric liner. This jig might also impart heat, vibration, sonic waves or other action to activate or enhance or speed adhesion.

[0056] Various processes and machines for preparing“ships-flat containers” and“form- on-demand containers” will be now described. The processes and machines may be used with various“ships-flat containers” and“form-on-demand containers”, for example the cup 100 described above, or a bottle (as described below), or another drinking container (e.g. the containers as shown in US 10,189,604 B2), and such containers can optionally include a lid or spout, and/or optionally can be filled aseptically and/or sealed prior to use.

[0057] In some examples, prior to expansion, the containers may be printed on. For example, the containers may be stored at their point of use (e.g. a coffee shop or drink dispensing machine) in the flattened configuration, within a printing machine. Referring to Figure 6, when ready for use, a container may drop from a hopper 602 into a print area 604 of the printing machine 600. In the print area 604, with the container still in the flattened configuration, the container may be printed on (e.g. using a digital, inkjet, or laser printer). The container may be printed with, for example, artwork, and/or advertising (e.g. a logo), and/or an indication of the contents with which the container will be filled (e.g. an ingredient list or the name of the drink), and/or a barcode or a QR code or other type of code, and/or a customer name. In some examples, the barcodes can be used as part of a promotion. For example, unique barcodes can be printed on each container. The end user (e.g. a purchaser of a drink) can use a portable device (e.g. a smart phone) to scan their code to see if they have won a prize, or to store points for each purchase made. Alternatively, the code could be scanned for another purpose, for example to gain entry to an event. In the example shown, after printing, the container is passed to a dispensing region 606 of the printing machine 600, where it may be retrieved by a user for subsequent use.

[0058] In some examples, the container may be printed in a single machine that prints the container and then expands the container (e.g. using the methods described above) and then fills the container. Alternatively, the single machine may print the container, and then expand and fill the container in a single step (e.g where filling causes expansion, e.g. in the case of a bottle that is filled by injection). An example of such a single machine 700 is shown in Figure 7, which includes a hopper 702 for storing flat cups, a print area 704 for printing the cups, an aseptic filling and sealing area 706, a touch screen 708 for controlling the machine (e.g. for ordering drinks), and a dispensing area 710 where a printed, expanded, and filled container is dispensed.

[0059] In an alternative example, a machine similar to that of Figure 6 can pass the printed containers to a secondary machine that expands and fills the containers. Such a secondary machine would be similar to that of Figure 7, but with the hopper and print area in one machine, and the filling and sealing area, touch screen, and dispensing area in a second machine, with a mechanism for passing containers from the first machine to the second machine.

[0060] Optionally, any of the machines described above can also seal the container or place a lid on the container. [0061] Optionally, in the above examples, the container can be provided with a product precursor, for example a beverage concentrate, contained therein. In such examples, the product precursor can optionally be sealed within the container by sealing shut the liner layer (e.g. vacuum sealing) around the product precursor. The machines described above can then reconstitute the product precursor, for example by expanding the container and opening the sealed liner layer, and filling the cup with water (or another liquid).

[0062] In the above examples, the container can be used for products other than drinks, such as detergent or soap, or a home care product, or a personal care product, or infant formula, or an auto care product, or a yard care product or a pet care product.

[0063] Referring now to Figures 9A, 9B, 10A, and 10B, another container is shown. The container of Figures 9A to 10B is also a“ships-flat container” and a“form-on-demand container”, and is in the form of a bottle 900. In Figures 9A and 9B, the bottle 900 is shown in a flattened configuration, and in Figures 10A and 10B, the bottle 900 is shown in an expanded configuration. Similarly to the cup 100, the bottle 900 includes a plant-based structural layer 902 (further details of which are described in detail in US 10, 189,604 B2), which includes a pair of flexible side panels 904, 906, that are joined together along their side edges, and an end cap 908 (visible in Figure 10A). The end cap 908 can be joined to the side panel 904 by a flexible hinge (not shown) and to the side panel 906 by a tab (not shown) that is folded along a fold line, in the same manner as described above and as shown in Figures 1 and 2. A pre-formed polymeric liner 910 (shown in Figure 1 1 ) is secured to the structural layer 902 and lines the inner surface of the structural layer 902, in the same manner as described above and as shown in Figures 1 and 2. Referring to Figures 9A and 9B, when the bottle 900 is in the flattened configuration, the flexible side panels 904, 906 lie generally flat against each other, the cap 908 is generally parallel to the side panels and lies generally flat between the side panels 904, 906, and the liner 910 is crushed between the panels 904, 906. Referring to Figures 10A and 10B, when the bottle 900 is in the expanded configuration, the cap 908 pivots downwardly about the hinge and the tab unfolds, and the side panels 904, 906 flex outwardly (as described above and as shown in Figures 1 and 2). The tab can be sized so that when it is completely unfolded, the cap 908 is perpendicular to the side panels 904, 906. When the tab is completely unfolded, the adhesive region of the tab can contact the adhesive region of the side panel, to adhere the tab to the side panel and hold the container 900 in the expanded configuration.

[0064] Referring to Figure 1 1 , in the example shown, the plant based structural layer 902 includes three sub-layers: a first sub-layer 912 that forms the inner surface, a second sub layer 914 that forms the outer surface, and a third sub-layer 916 between the first sub layer 912 and second sub-layer 914. The first sub-layer 912 is coarse-grained, the second sub-layer 914 is fine-grained (e.g. to facilitate printing thereon), and the third sub layer 916 is an insulation layer.

[0065] Referring back to Figures 9A and 10A, in the example shown, the bottle 900 includes a base portion 918 and a neck portion 920. The neck portion 920 is narrower than the base portion 918, and is configured to receive a lid 922 (shown in Figure 10A) of the bottle 900. The lid 922 can be, for example, adhered to the neck portion 920 or secured to the neck portion 920 by friction. The lid can be, for example, a sport-cap.

[0066] In the example shown, the bottle 900 is asymmetrical. That is, the neck portion 920 is offset to the side of the bottle 900. As will be described below, this can facilitate compact storage and shipping of the bottle 900.

[0067] Referring to Figures 12 and 13, the bottle 900 can optionally be sold as a set. Preferably, the set includes a first bottle 900a and a second bottle 900b. When in the flattened configuration, the first bottle 900a and the second bottle 900b can be aligned to form a rectangle - i.e. with the first bottle 900a inverted with respect to the second bottle 900b, so that the neck portion 920a of the first bottle 900a nests against the base portion 918b of the second bottle 900b, and vice versa. The first bottle 900a and second bottle 900b can be secured together in this rectangular configuration, to form a flattened rectangular package 924. For example, the first bottle 900a and the second bottle 900b can be secured together using an adhesive tape 926 on a first surface thereof, as shown in Figure 12, and on a second surface thereof, as shown in Figure 13. The adhesive tape 926 on the second surface can be in the form of a mailing label 928, and the rectangular package 924 can be shipped in the form shown in Figures 12 and 13, optionally without any further packaging. As used herein, the term rectangle is intended to include square. Alternatively, the rectangular package 924 can be shipped in another package such as an envelope or box 930, as shown in Figure 14.

[0068] In one particular example, the first bottle 900a and second bottle 900b can be loaded with a small amount of a product precursor, for example by a manufacturer or retailer. For example, the product precursor can be a concentrate (e.g. in the form of a liquid or solid or powder) such as detergent or soap concentrate, or beverage concentrate, or a home care product concentrate, or a personal care product concentrate, or an infant formula concentrate, or an auto care product concentrate or a yard care product concentrate or a pet care product concentrate. In another example, the product precursor can be a compacted product such as compacted paper towels or diapers or fabric softener sheets, which can be compacted by vacuum sealing the precursor product in the liner. The volume of product precursor can be relatively small - i.e. a small amount of concentrate can be used, or the product precursor can be highly compacted - so that the bottles 900a, 900b can remain in the flattened configuration. The first bottle 900a and the second bottle 900b can be sealed (e.g. by sealing the inner liners or with two lids 922, as shown in Figure 10A) and secured together to form the rectangular package 924. The rectangular package 924 can then be shipped to an end user, e.g. a consumer. The bottles 900a, 900b can then be separated by the user, and configured to the expanded configuration, and the contents can be reconstituted (e.g. by filling with water or another liquid, or by allowing or blowing air into the bottles). The set of containers shown in Figures 12 and 13 can allow for compact shipping, can minimize waste, and can facilitate e- commerce.

[0069] In any of the above examples, the containers can include pleats to facilitate flattening and expansion. An example of such a Figure 15, where container 1500 includes a structural layer 1502 pleats 1532. In such examples, the containers can move from the flattened configuration to the expanded configuration by unfolding of the pleats to cause outward movement of the side panels (as opposed to by flexing of the side panels). [0070] In any of the above examples, rather than the end cap 108 as shown in Figures 1 to 5, an end cap can be a separate piece that is joined to the container, for example manually or mechanically (e.g. by a vending machine). An example of such an end cap is shown in Figure 16, where container 1600 includes an end cap 1608 that is a separate piece from the liner layer 1616 and from the side panels 1604, 1606 of the structural layer 1602. The end cap 1608 includes a set of tabs 1612 that each include an adhesive covered region 1618 (shown in dotted line), which can contact and adhere to the structural layer 1602.

[0071] In any of the above examples, the liner layer can be sealed, optionally vacuum sealed, with a product or a product precursor contained therein, prior to shipment to a consumer. In the case of a product precursor, the product precursor can be reconstituted by a consumer, or at the point of sale. For example, a vending machine can reconstitute a product precursor, and then dispense the reconstituted product (optionally with a lid applied to the container). This can be done on demand by a vending machine.

[0072] In any of the above examples, the liner layer can be preformed and then joined to the structural layer, and can be and separable from the structural layer. Alternatively, the liner layer can be formed directly on the structural layer (e.g. can be coated onto the structural layer).

[0073] In any of the above examples, the outside of container can have a moisture proof cladding or coating. Furthermore, in any of the above examples, the polymeric liner can be on a fibre carrier sheet.

[0074] In any of the above examples, a water-proof and/or water-resistant coating or layer may be applied to the outside surface of the structural layer. Such coatings and layers can include plant-based waxes, and/or cellophane, and/or silicone-coated or plant-based wax coated fibrous materials, and/or plastic films.

[0075] While the above description provides examples of one or more processes or apparatuses or compositions, it will be appreciated that other processes or apparatuses or compositions may be within the scope of the accompanying claims. [0076] To the extent any amendments, characterizations, or other assertions previously made (in this or in any related patent applications or patents, including any parent, sibling, or child) with respect to any art, prior or otherwise, could be construed as a disclaimer of any subject matter supported by the present disclosure of this application, Applicant hereby rescinds and retracts such disclaimer. Applicant also respectfully submits that any prior art previously considered in any related patent applications or patents, including any parent, sibling, or child, may need to be re-visited.