bottle

Abstract

A bottle characterized by a tubular body portion (13) integrally formed by a spiral winding tube manufacturing process. A shoulder portion (11, 15) is joined to a first end of the body, and a base portion (14) is joined to an opposite second end of the body portion. The shoulder portion includes an inner shoulder (15) and an outer shoulder (11) that provide mutual support for a neck portion (12) and provide a structurally common beverage package shape, such as a flat bottle or a bottle. The neck portion can include a frustoconical end portion (26) that engages a mating surface (23) of the inner shoulder (15).

Description

Technical Field

[0001] This invention relates to a bottle made primarily of paper, which minimizes the use of plastic. The bottle is a form of consumer packaging suitable for containing liquids such as beverages. Background Technology

[0002] Reducing the use of plastics in consumables, especially packaging, is desirable. Trays and simple shapes are often made from pulp, but more complex items and items that need to contain liquids are more difficult to design.

[0003] Bottles made from substantial paper constructions have been proposed. For example, US10526120 describes a strategy for assembling a shoulder assembly to a body. The shoulder and body of the bottle are made of thermoformed pulp, but cannot be manufactured as a single piece due to manufacturing process limitations. A neck portion made of bioplastic is attached to the shoulder, which then fits and is attached to the body. The purpose of this bottle is that, due to its substantial paper construction and bioplastic neck, it is biodegradable.

[0004] Another example of a paper-based bottle is known from US2020407100, characterized by a spirally wound paper body. The shoulder construction is relatively rudimentary, with limited consideration for strength and aesthetics. Summary of the Invention

[0005] The present invention aims to provide a bottle made primarily of paper, which is an improvement or at least an alternative to known manufacturing methods. Ideally, the paper content and structure are sufficient to meet current and future recycling requirements in the paper recycling stream.

[0006] As determined by the inventors, a technique for manufacturing the body of a paper-based bottle involves spirally winding paper sheets to form a tube. This technique has been known for decades in the production of protective cylinders (e.g., for posters / artwork), as cores for roll products (e.g., tape or wrapping paper), and in some packaging solutions. Indeed, prior art example US2004052987 proposes a can structure in which the sidewalls are spirally wound paper. However, for use as a bottle, it is necessary to assemble a suitable shoulder / neck and base. Furthermore, the entire container must be liquid-sealed to be suitable for storing beverages and other liquids.

[0007] In a broad aspect of realizing the invention, the bottle according to claim 1 is defined. The method of manufacture according to the invention is defined at claim 22. Other useful features are outlined in the dependent claims.

[0008] The invention is most broadly considered to be a bottle consisting of three main components: a tubular body integrally formed by a manufacturing process (such as a process for manufacturing helical wound tubes or cores); a shoulder (which may include a neck or a neck fitting provided therethrough); and a base fitting. These three components are assembled to form a substantial bottle shape. The "bottle" shape refers to the shape of the shoulder having a neck portion that transitions to a narrower (typically smaller diameter) section than the substantial body, which provides most of the volume for storing the liquid. The base provides the surface on which the bottle can stand upright. The helical wound paper manufacturing process enables the production of a relatively strong and rigid body (e.g., generally not laterally compressible and very strong for vertical stacking), which achieves the high-quality finished product required for high-value liquids. The thickness of the body wall can be selected based on the number of rolls performed during the manufacturing process (e.g., 2.5 mm). The helical construction differs from a pulp body, which necessarily has thinner walls (e.g., 1 mm) that are easily subjected to lateral compression and are difficult to form into an elongated shape. Furthermore, the paper forming the spiral winding body can come from recycled sources, while the pulp body is more likely to be produced from virgin pulp.

[0009] The shoulder, neck, and / or base portions can be formed from multiple parts using a suitable process (most preferably a pulp-based method, such as compression molding). It is currently anticipated that, if not formed from paper, at least the neck portion may need to be molded from common plastics (such as PET, HDPE, or PP) exhibiting satisfactory torque strength to the threads. The primary example of the shoulder construction described herein includes a two-part construction: an inner shoulder and an outer (or upper) shoulder. The upper shoulder covers / conceals the edge of the inner shoulder that connects to the body.

[0010] However, it is worth noting that the upper shoulder is at least partly for aesthetic reasons and does not necessarily need to form a closure on the body to accommodate the contents. Therefore, the robust “inner shoulder” formed by pulp thermoforming can stand alone as a novel construction in combination with the body, back, and neck (in this context).

[0011] In one form, the neck fitting may have a snap-fit ​​feature that is heat-sealed to the shoulder portion. For example, a snap-fit ​​ring is snap-fitted onto the neck fitting to clamp the surface of the shoulder between the shoulder itself and a flange at the end of the neck fitting near the body. Alternatively, the neck fitting may be threaded or glued to the shoulder.

[0012] The substantial shoulder component can be heat-sealed to the body. The upper shoulder can be decorative and / or provide reinforced structural support for the neck and inner shoulder components heat-sealed to the body. Preferably, the upper shoulder is tightly secured to the main / inner shoulder component, thereby providing strength to prevent the neck fitting from being pushed open under top load. Alternatively, the component can be sonicated or screwed onto the fitting. In a further form, a spacer insert can space the shoulder component (i.e., the component that serves as the end portion of the body) from the outer "upper shoulder".

[0013] In one embodiment, the inner surfaces of the various components are coated or laminated with a heat-sealable layer, at least at the contact / seam areas. Lamination is currently the preferred method, but spraying can also be optimized for use in this invention depending on the application. In a further embodiment, an inner bag may be provided.

[0014] As mentioned earlier, in order to assemble the neck to the shoulder, either the neck insert is molded into or onto the shoulder, or the neck may comprise two parts: a main section and an inner section. These parts can be screwed / threaded, welded, glued, or snap-fitted together to clamp the shoulder between them.

[0015] The main body can be a tube with any cross-section (e.g., circular (the most common bottle shape), rectangular (flat bottle shape), "square" (usually square but with rounded corners), or any other closed geometry); that is, in principle, a tube made of spirally wound layers of paper can take any form of closed cross-section. The inner layer can be a barrier layer to prevent liquid from flowing out. Decorative / logo material can be printed directly onto the outer layer or incorporated into the sleeve surrounding the body, which may be heat-shrinkable and overlap the shoulder and base.

[0016] In certain forms, the shoulder portion is an end / cap made of thermoformed pulp. It may include a central opening to receive a neck fitting. Similarly, the base portion may be an end made of molded paper / card or pulp to close the opening of the body tube.

[0017] In one form, the neck is a threaded fitting made of a recyclable or at least separable material such as PET, HDPE, or PP, providing a pouring spout and threads for securing the cap. The neck portion can alternatively be adapted to other closure types, such as corks or resealable openings (e.g., "sipper bottles").

[0018] In one form, the body and base can be rolled / sewn together. In another form, the body and shoulder can be butt-jointed at the edges of the same cross-section, wherein, preferably, before joining the body and base, separate ring parts are glued to the inside of the two parts, ultimately completing / closing the shape of the bottle.

[0019] While seams may be visible, the shoulder and body can have a smooth / continuous transition across the entire outer surface of the packaging, between the shoulder and body, to achieve a traditional bottle or flat bottle shape. A sleeve / label layer can be applied to cover any other visible joint between the shoulder and the tubular body. Attached Figure Description

[0020] Figure 1 The illustration shows an external perspective view of a bottle structure based on the principles of the present invention;

[0021] Figure 2 and Figure 3 The diagrams illustrate the following: Figure 1 Front and side sectional views of the bottle;

[0022] Figure 4 The illustration shows an exploded view of the bottle's structural components from above;

[0023] Figure 5 A series of side sectional views illustrating the assembly method from the neck to the shoulder are shown;

[0024] Figure 6 and Figure 7 The illustrations show exploded perspective views of components of another embodiment of the invention, viewed from above and below; and

[0025] Figure 8 The illustration shows an exploded perspective view of the components of an embodiment of the "rounded square". Detailed Implementation

[0026] The following description presents exemplary embodiments, and is consistent with the appendix. Figure 1 This description is intended to explain the principles of the invention. However, the scope of the invention is not intended to be limited to the precise details of the embodiments or strict adherence to all steps, as variations will be apparent to those skilled in the art and are considered to be covered by the description. The terminology used for components herein should be interpreted broadly to include equivalent functions and features. In some cases, several alternative terms (synonyms) for structural features have been provided, but these terms are not intended to be exhaustive.

[0027] Descriptive terms should also be interpreted as broadly as possible; for example, the term "comprising" as used herein means "consisting of at least part of," such that in interpreting each statement in this specification that includes the term "comprising," other features may be present besides that term or those preceding it. Terms related to "comprise" and "comprises" will be interpreted in the same manner. Directional terms such as "vertical," "horizontal," "upward," "downward," "upper," and "lower" are used for ease of interpretation and are generally referenced to illustrations; they are not intended to be ultimately limiting if equivalent functionality can be achieved with alternative dimensions and / or orientations. The term "tubular" as used herein generally refers to an elongated / extruded hollow shape, although a tube may have a diameter greater than its length. The cross-section of a tube may be circular or any other closed shape.

[0028] The description herein refers to embodiments with a specific combination of manufacturing steps or features; however, it is conceivable that further combinations and cross-combinations of compatible steps or features between embodiments will be possible. In fact, a single feature can function as an invention independent of other features and does not necessarily need to be implemented as a complete combination.

[0029] Figures 1 to 4 The illustration shows a schematic diagram of a flat-bottomed bottle. Specifically, the bottle 10 includes a shoulder portion 11 and a neck 12, the shoulder portion 11 being attached to a tubular body 13. The body 13 is formed by a manufacturing process in which continuous sheets of paper are spirally wound onto a rotating core using adhesives and / or compressive force. In this way, the spirally wound body will have superior strength compared to walls formed, for example, from compressed / thermoformed pulp, resisting both lateral compression / squeezing of the bottle sidewalls and vertical stacking.

[0030] The base portion 14 provides an end closure that abuts against the body 13 and a surface on which the bottle can stand upright.

[0031] Depend on Figure 2 A side elevation sectional view of the flat bottle is shown. The shoulder 11 is preferably formed from pulp using a molding process, forming a structure including edges to provide a surface for heat sealing against the body 13. The neck 12 may be co-molded into the shoulder 11, or, as illustrated, formed from several components that join the upper shoulder 11 and the inner shoulder to provide structural strength.

[0032] The base 14 may include grooves or channels that mate with the body 13, but since the base is mostly concealed during use (i.e., for minimal aesthetic considerations), the peripheral flange 18 in contact with the ground is sufficient to provide stable support, allowing the bottle to stand upright. Clearly, the upright wall 19 of the base 14 provides sufficient surface for the heating tool to clamp onto the adjacent wall of the body 13.

[0033] Figure 3 and Figure 4 It shows Figure 2 Further internal details of the shoulder arrangement are shown. Specifically, shoulder 11 is an outer shoulder molded part that provides a smoother, rounded corner appearance, which is fitted onto the inner shoulder portion 15 that provides the main structural support.

[0034] As by Figure 2 and Figure 3 As illustrated, there is a noticeable air gap between the substantial surfaces 11 and 15; however, in one embodiment, the lower portion of surface 11 may contact (i.e., clamp) at least a portion of the inner shoulder 15, for example, at contact point 16.

[0035] Reference Figure 4 , Figure 4 The illustration best illustrates how the components of the bottle assembly are assembled, with the substantial flat bottle volume for holding liquid defined by an inner shoulder portion 15 and closed by a base 14, the inner shoulder portion 15 being configured for connection to a tubular body 13. The body 13 is shown in dashed lines to represent any elongated, continuous tubular shape. The base portion 14 provides an end closure abutting the body 13 and a surface on which the bottle can stand upright.

[0036] As previously described, the shoulder structure includes an inner shoulder 15 and an outer shoulder 11 for improving structural rigidity, wherein the outer neck fitting 12 abuts against an outer opening 17 in the outer shoulder 11 via a proximal flange 20. An annular flange 21 located in the middle of the neck provides a ridge for receiving a locking safety feature such as a torsion cap closure. An inner opening 22 at a frustum-shaped support 23 extending from the center of the inner shoulder 15 abuts against and aligns with a contact surface 16. Figure 2 The other (inner) side of the opening 17 at the location. The first / outer neck fitting 12 is secured by coupling with the second inner neck fitting 24, which includes a tubular element 25 and a truncated base 26 that flares out generally from the tubular wall 25.

[0037] Sectional view Figure 2 and Figure 3The tubular element 25 of the second neck fitting is shown to be received by the inner bore of the first neck fitting 12, while the tapered frustum surfaces 26, 23 engage and form a butt joint and anti-torsion feature. In other words, the shapes of the mating, generally hexagonal bases of the frustum pyramids engage and provide structural support to prevent the second neck fitting 24 from twisting relative to its longitudinal axis. The first neck fitting 12 can be keyed to the second neck fitting 24, and / or in any case can be glued or sonicated.

[0038] One or more ribs 27 (mimicking the clavicle) extending radially from the truncated support 23 provide additional rigidity to the inner shoulder 15. As is evident in the combined configuration, the upper shoulder 11 (primarily for aesthetic purposes) provides structural strength to support the edge 28 abutting the inner shoulder 15, allowing multiple components to be formed from pulp, thus making the entire product substantially recyclable. The edge 28 provides a flange that can be adhered / welded to the top opening edge of the body 13. Supporting the edge 28, the outward-facing upright wall 29 forming an integral cup shape with the inner shoulder 15 also provides a surface for connection / bonding to the helical body 13.

[0039] The structure of the shoulder 15 can be considered as a separate, separable invention for combination with the body 13 and the neck 12 to include a bottle; that is, a cup-shaped end for receiving into and adhering to the inner wall of the open end of the body 13, optionally including support ribs radiating from the anti-torsion neck support element.

[0040] In an alternative form, the neck structure may include additional spacer layers or wall layers. If the manufacturing process allows, the upright neck portion may be integrally formed with the inner shoulder. Similarly, the upright neck may be formed together with the outer shoulder. In this way, the neck of the inner shoulder may be partially joined to the neck of the outer shoulder to connect the inner and outer shoulders together. Further internal ribs may engage to provide contact surfaces (e.g., for joining) between the components.

[0041] according to Figure 5 The figure illustrates alternative forms of the neck, in which, for example, a neck molded part 12 of ordinary plastic may include a flange 30 at an end near the body 13, which performs a mating feature when the neck 12 is inserted through an opening 17 in the surface of the portion 15. In this example, the flange 30 may be heat-sealed or glued to the shoulder 15, or alternatively secured by a physical component such as a retaining ring 31, which snaps onto an annular ridge 32 extending around the perimeter of the neck 12. Figure 5 The bottom cross-sectional view shows the shoulder 15 and the decorative outer layer 11 sandwiched between the flange 30 and the ring 31.

[0042] The neck 12 may include threads for a cap or other sealing device such as a cork or a self-closing hole.

[0043] Figures 6 to 8 Two additional embodiments of the bottle according to the invention are shown, namely, a cylindrical body and a "rounded square" body, respectively. The same reference numerals are used to indicate the same structural features, such as the upper shoulder 11, neck 12, body 13, base 14, inner shoulder 15 with edge 28, and upright contact wall 29 for adhesion to the inner wall of body 13.

[0044] The neck 12, as described above, includes an outer tubular element (for receiving the lid) and an inner element 24 configured to pass through an opening 17 in the inner shoulder 11 and / or an opening 22 in the outer shoulder 15.

[0045] exist Figure 6 and Figure 7 Of particular note in the illustrated embodiment is the protruding nature of the internal structure of shoulder 15, which matches the corresponding annular receiving surface of upper shoulder 11. In this example, the radial ribs 27 around the central post 33 serve as mutual positioning elements and stiffness reinforcements when received into upper shoulder 11. In some forms, the substantial surfaces of the ribs of the inner and outer shoulders can be clamped together to form a particularly robust / reinforced shoulder configuration.

[0046] The bottle of the present invention preferably has a liquid-resistant interior, i.e., such a container is suitable for filling beverages. The protective layer can be applied to the inner surface using, for example, a spray gun through the neck, or the layer can be integrated with the paper material used for each component. Alternatively, a collapsible bag can be housed within the body 13 and sealed with the neck 12. This bag (and associated common plastic neck fittings) is preferably removable during separation for recycling.

[0047] This invention can be summarized as a bottle-making process and related products. The bottle comprises a tubular body portion integrally formed by a spiral winding tube manufacturing process. The cross-section of the body portion can be selected from a variety of closed shapes (e.g., circular, square, rectangular, triangular). In fact, any polygonal or curved shape is acceptable. A two-piece reinforced shoulder construction is attached to a first end of the body portion, and a base portion is attached to the opposite second end of the body portion. The two-piece shoulder includes an inner shoulder and an outer shoulder, which provide mutual support for the neck and provide a structurally familiar beverage packaging shape, such as a flat bottle or bottle. The neck portion may include a flared end, for example, frustum-shaped, that engages with a mating surface of the inner shoulder. Reinforcing elements (such as ribs) may be provided on one or both of the inner and outer shoulders, which may optionally engage together for further reinforcement.

[0048] The invention, separable from this application, can be considered as a shoulder structure formed solely from the pulp of the "inner shoulder 15". In other words, the cup-shaped shoulder structure, embedded in and abutting against the tubular body wall, includes: a peripheral flange / edge 28 for connecting / joining to the top opening edge of the paper-made body, and an outwardly facing upright wall 29 for joining to the inner wall of the body 13. The shoulder may include support ribs extending from a central neck support portion, which are, for example, formed in a frustoconical shape for coupling with a complementary portion of the neck assembly. The frustoconical or equivalent non-circular matching shape provides increased torque and top load strength to the neck.

Claims

1. A bottle comprising: A tubular body portion, the tubular body portion being formed of paper, the tubular body portion having a first open end and a second open end; A shoulder portion, which is joined at the first open end of the tubular body portion, provides a transition from the tubular body portion to a neck portion, the neck portion being configured to receive a closure; as well as The base portion is joined at the second open end of the tubular body portion; The shoulder portion comprises two parts: A reinforced inner shoulder, formed from paper as a separate component, having a reinforcing element, is attached to the tubular body portion at the first opening end along its continuous periphery connecting edge. An outer shoulder, formed from paper as a separate component, is attached to at least one of the inner shoulder and the tubular body portion, and is configured to cover the inner shoulder.

2. The bottle according to claim 1, wherein, The tubular body is integrally formed using a spiral winding tube manufacturing process.

3. The bottle according to claim 1, wherein, The inner shoulder, the outer shoulder, or both are formed by a pulp-based molding method.

4. The bottle according to claim 1, wherein, The neck portion is integrally formed with the inner shoulder portion or the outer shoulder portion.

5. The bottle according to claim 1, wherein, The neck portion is a separate piece molded from pulp, PET, PP, or polyethylene and attached to the shoulder portion.

6. The bottle according to claim 5, wherein, The neck portion includes a tubular body and a flange at one end of the tubular body; and the shoulder portion includes an opening for receiving the tubular body through the opening of the neck portion, while the flange abuts the shoulder portion around the opening.

7. The bottle according to claim 6, wherein, The tubular body of the neck portion includes surface features received by mating features of a ring member configured to surround the neck portion such that the shoulder portion is sandwiched between the flange and the ring member.

8. The bottle according to claim 7, wherein, The surface feature is an annular ridge or a thread.

9. The bottle according to claim 1, wherein, The neck portion includes at least one neck accessory having a tubular portion and a flared portion for engaging with a mating portion of the inner shoulder.

10. The bottle according to claim 9, wherein, It also includes an outer neck fitting for receiving the tubular portion.

11. The bottle according to claim 9, wherein, The flared portion and the mating portion are truncated.

12. The bottle according to claim 1, wherein, The outer shoulder also includes reinforcing elements.

13. The bottle according to claim 12, wherein, The reinforcing elements, which are in the form of ribs, of the inner shoulder and the outer shoulder are fitted together.

14. The bottle according to claim 1, wherein, The inner shoulder includes at least one wall or flange, which is configured to be heat-sealed, glued, or welded to the tubular body portion.

15. The bottle according to claim 1, wherein, The base portion is sewn and wound onto the tubular body portion.

16. The bottle of claim 1, comprising an internal protective coating or laminate to prevent liquid leakage.

17. The bottle of claim 1, further comprising an inner bag to prevent liquid leakage.

18. The bottle of claim 1, further comprising an outer sleeve for covering at least a portion of the tubular body portion.

19. The bottle according to claim 18, wherein, The outer sleeve further covers the junction between the tubular body portion and the shoulder portion and / or the base portion.

20. The bottle according to claim 18, wherein, The outer sleeve has heat-shrinkable properties.

21. A method for manufacturing a bottle, comprising the following steps: Prepare or provide a tubular body portion integrally formed by a spiral winding paper tube manufacturing process; The base portion is attached to the second opening end of the tubular body portion; A shoulder portion is provided to facilitate the transition from the tubular body portion to the neck portion configured to receive the closure, the shoulder portion comprising a two-part structure via: The reinforced inner shoulder, formed from molded pulp as a separate component and having reinforcing elements, is joined to the first open end of the tubular body portion at its continuous perimeter connecting edge. as well as An outer shoulder, formed as a separate component from molded pulp, is attached to at least one of the inner shoulder or the tubular body portion, the outer shoulder being configured to cover the inner shoulder.

22. The method according to claim 21, wherein, The inner shoulder and the outer shoulder have mating surface features that are aligned during the joining process.

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