CROSS-REFERENCE TO RELATED APPLICATIONThis application claims priority from U.S. Provisional Patent Application No.[0001]60/235,690, filed on Sep. 27, 2000 under 35 U.S.C. §119(e).
FIELD OF THE INVENTIONPackaging and storage of concentrated liquids and solids and the hydrated/reconstituted product thereof.[0002]
BACKGROUND OF THE INVENTIONMany products, especially beverages, such as fruit juice, milk, proportionally are largely composed of substantially inert liquids, such as water. Correspondingly, the proportion of solid material comprising beverage products is quite small. For various reasons, such as reduced cost of transportation, ease of transportation and storage and the extension of shelf life, such products are dehydrated wherein the inert liquids are extracted. Such products are reduced into concentrated liquids or solidified before distribution. The dehydrated liquids or solids are transported through the product distribution chain, eventually arriving at repackaging/bottling plants or consuming locations. At these locations, the products are rehydrated, whereat inert liquids, such as water, are added into the dehydrated liquids or solids to restore the original products.[0003]
Many other products, including medicines and chemicals, are made from precursors in liquid or solid forms. The desired end products are prepared by mixing the precursors with additional liquids, often water or alcohol. Reference to “concentrated liquids or solids” in this application means liquids or solids having less liquids than the hydrated, rehydrated, reconstituted or desired products. The hydrated, rehydrated, reconstituted or desired products are the end products for use or consumption. The concentrated liquids or solids can be produced by a dehydration process from the hydrated products or from precursors. The rehydration process in this invention refers to any processes where a liquid is added to a concentrated liquid or solid.[0004]
The rehydration process can be carried out at a central location near consumers, such as at a local bottling company, at a restaurant, or at other consuming sites, such as a consumer's home, a camping ground, a hospital room or a research laboratory. The rehydration process usually involves measuring the correct amount of concentrated liquid or solid and the correct amount of the diluting liquid, then mixing them together in a suitable container. If the amount of hydrated product is large, it may need to be divided into smaller sized containers for consumption and/or storage for future consumption.[0005]
Many steps in the rehydration process, such as measuring of the concentrated solid or liquid, measuring the diluting liquid, transferring concentrated solid or liquid between different containers, etc. are not very convenient to perform. In this regard, a measuring cup may be hard to locate when a crying baby wants formula or a patient urgently requires medicine. The accuracy of the measurement can be a problem in many circumstances. Also, inadvertent spills of concentrated liquid or solid powder when pouring from bottles into cups or other mixing containers may be messy.[0006]
Various devices have been developed in an attempt to address the different aspects of the rehydration process. For example, small amounts of instant coffee powder are packaged in packets for a certain sized cup. For consumption, the packet is opened and then the coffee powder is poured into a cup. Water is added to fill the cup and the mixture stirred to make a cup of coffee. No measuring of the coffee powder or water is necessary. But the concentrated liquid or powder still needs to be poured into a separate mixing and drinking cup of the proper size. Also, this process is environmentally wasteful if a disposable mixing/drinking cup is used. disposable cup has been used as the package for the concentrated liquid or solid, so no additional cup is necessary. Water is added to the cup to produce the desired product. But the cup typically significantly increases the volume of the package for the concentrated liquid or solid because the cup must have sufficient volume to accommodate the end product. The relatively large volume or size of the cup reduces the benefit of using a concentrated liquid or solid.[0007]
Instead of a rigid cup, the package for concentrated liquids or solids can be composed of a flexible material and function as an insert for another container serving as a shell. To produce the product from the concentrated liquid or solid, the flexible package is placed in the shell container. The package is opened and water or other diluting liquid is added to the package. The shell container provides support and protection for the end product.[0008]
The forgoing packaging materials are typically composed of paper, plastic, or a combination thereof. Paper is a natural product and environmental friendly. But paper is usually not very strong. Also, it is a poor liquid or vapor barrier. Plastic, such as polyolefin, is durable, strong, and a good barrier for liquid or vapor. But plastic can be very slow to decompose, thereby accumulating in landfills and causing environmental problems.[0009]
SUMMARY OF THE INVENTIONThe present invention advantageously provides a package for concentrated liquids or solids and the rehydrated products thereof. The package can be made from a sheet material folded and then sealed along all margins. The sheet material contains at least about 30 percent a mineral based material by weight. The package can have a resealable spout and/or a handle.[0010]
BRIEF DESCRIPTION OF THE DRAWINGSThe foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:[0011]
FIG. 1 is an isometric view of a first embodiment of the current invention, shown as holding a rehydrated product;[0012]
FIG. 2 shows a flat sheet that can be used to construct the first embodiment of the current invention shown in FIG. 1;[0013]
FIG. 3 is an isometric view of another embodiment of the current invention shown as filled with a rehydrated product;[0014]
FIG. 4 shows a flat sheet that can be used to construct the embodiment of the current invention shown in FIG. 3.[0015]
FIGS.[0016]5-10 show schematic views of a method of continuously constructing and using an embodiment of the current invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTFIG. 1 is an isometric view of a first embodiment of the present invention, including a[0017]container20 holding a rehydrated product. Thecontainer20 has abody21 section and abottom28 section. Aspout22 extends upwardly from the top of thebody21, aside spout23 is on the shoulder of thebody21, and one ormore finger holes26 are positioned between thebody21 and ahandle bar24.
FIG. 2 is a plane view of a[0018]flat sheet50 that can be used to construct thecontainer20 shown in FIG. 1, where the panels have not yet been folded and the margins thereof have not yet been sealed.
FIGS. 3 and 4 show another embodiment of the present invention in the form of a[0019]container30. Thecontainer30 is essentially constructed from aflat sheet40. Theflat sheet40 is generally rectangular in shape, and thus has a top, a bottom and two sides. The top has a top margin oredge portion32 extending therealong. The bottom has a bottom margin oredge portion38 extending therealong and the two sides have side margins oredge portions34 and36. Theflat sheet40 also has afold line31 extending along longitudinally between twopanels41 and42 comprising the sheet. When theflat sheet40 is folded along thefold line31, the twoside margins34 and36 ofpanels41 and42, respectively, meet, and the two panels define a space therebetween. When the overlapping margins of the two panels are sealed together, i.e.,margin34 tomargin36, thetop margin32 ofpanel41 to thetop margin32 ofpanel42, and thebottom margin38 ofpanel41 to thebottom margin38 ofpanel42, a sealed space is formed in between the two panels forming thecontainer30. The margins alongfold line31 can also be sealed.
When the concentrated liquid or solid alone is stored in[0020]container30, the container is essentially flat. It can be rolled or folded further to reduce its size if the sheet material is sufficiently flexible. When the diluting liquid is added to thecontainer30, the container expands and becomes generally pillow-shaped, as shown in FIG. 3. Designed with a spout, this type of container can conveniently be used as a portion pack that can easily be carried about, e.g., in a person's pocket or handbag.
Rather than constructing the[0021]container30 with twopanels41 and42 by folding theflat sheet40 over on itself, thepanels41 and42 can be individual members, e.g. provided from one or more continuous webs, that are sealed together along their margins.
When the flat sheet is cut into certain shapes or patterns, a more useful container can be formed. In an embodiment of the current invention shown in FIG. 2,[0022]flat sheet50 is cut into a specific shape. Theflat sheet50 is shaped to define three panels: a first or lefthand side panel100, a second or righthand side panel200 and a thirdbottom panel300. Theleft side panel100 andright side panel200 are generally rectangular in shape and form the body of thecontainer20. Thethird panel300 forms the bottom of thecontainer20 and is generally elliptical in shape.
The[0023]left side panel100 has aleft margin122, a top section, aright margin124 opposite to the left margin and also shares afold line126 with theadjacent margin224 of theright side panel200, and a bottom section which shares afold line128 with thebottom panel300. The top section ofpanel100 hassequential margin segments102,103,104,106,108,112,114 and116 which extend from theleft margin122 to theright margin124. The bottom section of theleft side panel100 hassequential margin segments132,134 and136 that extend from theleft margin122 to theright margin124.
Similarly, the[0024]right side panel200 has aleft margin224, which shares thefold line126 with theadjacent margin124 ofleft side panel100.Panel200 also has aright margin222 oppositeleft margin124, a top section and a bottom section. The top and bottom sections ofpanel200 are mirror images of the top and bottom sections ofpanel100. Similar to theleft panel100, the top section of theright side panel200 hassequential margin segments202,203,204,206,208,212,214 and216. Also, the bottom section of the right side panel has sequentiallower margin segments242,244 and246.
At the top section of the[0025]left side panel100,margin segments106,108 and112 cooperatively define an upwardly extending protrusion orspout section110. Similarly, at the top section of theright side panel200 themargin segments206,208 and212 cooperatively define an upwardly extending protrusion orspout section210. On the left shoulder of theleft side panel100, themargin segment103 together with thecorresponding margin segment203 on the right shoulder of theright side panel200 can conveniently form a side spout.
The[0026]left side panel100 also has anoblong hole156, outwardly adjacent and extending alongmargin segment116. The outer edge portion of this margin section is identified bypart numbers152 and154. The righthand side panel200 has a matchingoblong hole256, outwardly adjacent and extending alongmargin216. The outer edge portion of this margin section is identified bypart numbers252 and254. Theleft side panel100 has a second, generallyround hole159 positioned just upwardly of theoblong hole156. Correspondingly, a generallyround hole259 is formed in the marginal portion ofpanel200 just aboveoblong hole256. When thecontainer50 is assembled, as discussed below, theholes159 and259 are in registry, and theholes156 and256 are in registry. Thehole159/259 can conveniently receive the forefinger of the user, and theoblong hole156/256 can conveniently receive the middle, ring and/or small fingers of the user.
The[0027]bottom panel300 has amarginal section334, which shares afold line128 withmargin134 ofleft panel100. Thebottom panel300 also hasmargin segments332 and336 that extend diagonally away frommargin section334. Thebottom panel300 further hasmargin segments342,344 and346 that correspond withmargin sections332,334 and336. Afold line340 longitudinally divides thebottom panel300.
Although the[0028]margin segments334 and134 do not necessarily have to be straight, preferably at least a central portion of these margin segments is substantially straight and generally parallel to foldline340. Similarly,margin segment344 along the distal portion of thebottom panel300, andmargin segment244 at the bottom of theright side panel20, also are preferably centrally substantially straight and parallel to foldline340. It is further preferred, but not essential, thatmargin segments336 and346 ofbottom panel300 form an angle, which may be about 90 degrees and bisected byfold line340. Similarly,margin segments332 and342 preferably form an angle, which may be about 90 degrees and is bisected byfold line340.
When the[0029]container20 is assembled fromflat sheet50, the panels are folded alongfold lines126,128 and340 and then all the matching margin segments the three panels are sealed together. There are many ways to carry out the sealing process, whether by chemical or physical procedures. Perhaps one of the easiest physical techniques is by heat sealing using well known equipment and techniques. In this regard, heat is applied to the margin segments of the panels, fusing the sheets together to create a fluid tight seal. An example of a chemical technique is to use an adhesive to seal the corresponding margin segments together. The corresponding margin segment pairs between theleft side panel100 and theright side panel200 include:102/202,104/204,106/206,108/208,112/212,114/214,116/216,124/224,122/222,152/252,154/254. The corresponding margins between theleft side panel100 and thebottom panel300 include:136/336,134/224,132/332. Also the corresponding margins between theright side panel200 and thebottom panel300 include:242/342,244/344,246/346. The matching holes are156/256,159/259. The margins alongfold lines126 and128 may or may not be sealed.
Rather than employing the[0030]fold lines126 and128, thepanels100,200 and/or300 could be joined together along other marginal portions thereof, thereby to define other fold lines. For example, rather than being joined topanel100,panel200 could be joined topanel300 wherein the intersection betweenbottom margin244 ofpanel200 and thedistal margin344 ofpanel300 could define a fold line therebetween. In addition, the threepanels100,200 and300 could be formed as separate sheets that are joined together along their corresponding margins.
According to another embodiment of the current invention, the two side panels are connected to the third bottom panel but not to each other directly. In this arrangement, the[0031]flat sheet50 and thecontainer20 can be advantageously constructed by a continuous process, as shown in FIGS.5-10. Theflat sheet50 can be eventually cut from an endless sheet material. A roll of such endless sheet material is shown in FIG. 5. The endless sheet can be folded along the longitudinal axis to form a W-shaped endless sheet, which has two outer layers and two inner layers, as shown in FIG. 6. The outer layers will become the twoside panels100 and200 of theflat sheet50 and the inner layers will become thebottom panel300 of theflat sheet50. In this arrangement, the first andsecond side panels100 and200 do not share a common fold line, but each of them shares a common fold line with thebottom panel300. The shared fold lines are between margin segments of134/334 and244/344.
The W-shaped endless sheet will be punched and “welded” by heat sealing or other processes into the shape of a side panel of[0032]flat sheet50. Each individual flat sheet is still connected to each other in the W-shaped sheet, as shown in FIG. 7. All the corresponding side margins are welded or otherwise sealed to formcontainer20, except the seals at the spouts on top of theflat sheet50, as in FIG. 1. Aftercontainers20 are formed on the W-shaped endless sheet, the W-shaped endless sheet is rolled back into a roll composing ofmany containers20, as shown in FIG. 8. The roll of endless sheet ofcontainer20 can then be used in a continuous filling machine to be filled-in with the concentrated liquids or solids, as shown in FIG. 9. After eachcontainer20 is filled with correct amount of concentrated liquids or solids, theindividual container20 is evacuated and sealed. Thecontainers20 with concentrated liquids or solids can again form a roll as in FIG. 8 for storage or transportation. Or the containers can be cut out of the endless sheet as individual packages for storage, transportation or distribution, as shown in FIG. 10.
In another embodiment, when all the margins are sealed together, except[0033]margin segments108/208, thecontainer20 is ready for use. Thecontainer20, as assembled, has a nominally, substantially flat profile. When the container is assembled, access to the interior of thecontainer20 is through the unsealedtop margin segments108/208.
To use the[0034]container20 to store concentrated/dehydrated liquids or solids, a nozzle from a filling machine or apparatus can be inserted into thecontainer20 through the opening atmargin segments108/208. Once the correct amount of concentrated liquid or solid is dispensed into thecontainer20, the container can be evacuated and sealed atmargin segments108/208. Removing the air from the concentrated liquid or solid can result in the contents of the container to be preserved for a relatively long period of time. Depending on the volume of the concentrated liquid or solid, thecontainer20 can assume a relatively flat configuration and occupy minimal space when transported and/or stored.
When the contents in the[0035]container20 are ready to be used, the seal atline108/208 can be cut or otherwise broken. Thereafter, thecontainer20 can be filled with the diluting liquid (thereby expanding the container) to produce the desired product. The volume of thecontainer20 guarantees a correct amount of diluting liquid being filled into the container. Such guarantee of correct amount of diluting liquid is very important, especially in medical or nutrition substance applications. Thespout22 can then be closed or resealed. There are numerous ways to resealspout22. For example, it can be resealed with a cap, a plug or similar closure item. For a more permanent closure, a heat sealing iron can be used. Also, spout22, formed by theprotrusions110/210, can be held pressed together with a clip or pin.
The[0036]container20 can be shaken and/or turned upside down, etc., to mix the concentrated liquid or solid with the diluting liquid. Once the concentrated liquid or solid and the diluting liquid are well mixed, the end product is produced and ready for use. No measuring of the concentrated liquid or solid or the diluting liquid is necessary. There is no need to transfer concentrated liquid or solid from one container to another. The end product can be retained in the same container and can be sealed therein to extend the product's useful life, or maintain the freshness of the product, such as a food product.
The product can be dispensed directly from the[0037]container20 through thespout110/210 or transferred to another container. The product can also be preferably dispensed through a side spout by cutting or tearing the container atmargin segment23, as shown in FIG. 1. In this manner thecontainer20 can conveniently be handled like a jug when pouring the product from the container. The contents can be stored in thecontainer20. Due in part to the flatbottom panel300 and/or the substantially straight,parallel margin segments134/334 and244/344, thecontainer20 can sit on a flat surface by itself without having to be placed into another container. The angles formed bymargin segments332/342,336/346 also help the ends of thebottom panel300 to bend or extend upwardly evenly to join the adjacent margins of thepanels100 and200, thereby leaving the rest of the container bottom28 substantially flat and without bulges.
The[0038]handle24 can be used to conveniently carry thecontainer20. Unlike many existing single use/single serving containers, thespout22 can be advantageously resealed by various means to keep the contents of thecontainer20 fresh for an extended period of time.
Once all the contents in the[0039]container20 have been consumed or otherwise used, thecontainer20 can be easily flattened back to its original profile. Thecontainer20 can be further folded or rolled into an even smaller size.
In an embodiment of the current invention, the material used to construct the[0040]container20 may not have a “memory”, so that when storing the concentrated liquid or solid, thecontainer20 can be rolled or folded into a smaller configuration. Also, when adding the diluting liquid, thecontainer20 can readily expand. Later, after the restored product has been consumed or used, thecontainer20 can then be returned to a collapsed, flat configuration for disposal.
Also, in an embodiment according to the current invention, the material used to form the flat sheets may preferably be a combination of a mineral based filler material and a plastic binding material. A mineral based filler material, such as calcium carbonate is blended with a binding material, such as polyolefin or other plastic material, to form a homogenous plastic composition material. The plastic composition material has most of the characteristics of a plastic material, so the plastic composition material can be used in the same ways as other plastic materials are used.[0041]
For example, the plastic composition material can be formed into pellets for further applications, such as thermoforming, injection molding, film blowing or sheet extrusion. The plastic composition material can be made into homogenous films or sheets for packaging applications. The plastic composition material can be more advantageously used with other materials to form a laminated sheet material with more desirable properties for packaging applications. For example, the laminated sheet material can have an outer heat-seal layer, a plastic composition material layer, a UV barrier layer, a second plastic composition material layer, an oxygen barrier layer and a second heat-seal layer. The combined thickness of the layered material can range from 40 to 80 microns, or thinner or thicker depending on the need.[0042]
There are many advantages in using the plastic composition material of the present invention to form[0043]container20 instead of traditional plastic material, paper or their combination in packing applications. The mineral based filler materials are in abundant supply. A large portion of the filler/binder plastic composition material consists of the mineral based filler material. The mineral based filler material can be composed of calcium carbonate, which can come from chalk or dolomite or magnesium silicate which can be derived from talc or mica, or many other mineral based materials.
The mineral based filler/binder mixture decomposes much faster than common plastic materials. Once decomposed, the bulk of the mixture, which is the mineral filler, will return to its natural state, either in solid form such as chalk or talc, or dissolved in water.[0044]
Calcium carbonate is a desired filler material because it has certain advantages. It is one of nature's own construction material, such as in egg shells. Egg shells contain about 90% calcium carbonate by weight. (Unless specified otherwise, all percentages stated herein are percentage by weight.) Once it is used, the calcium carbonate can be dissolved by water or digested by living creatures as part of their food, so that the calcium carbonate is recycled or reused by nature itself, like egg shells.[0045]
Except that it decomposes much faster than common plastic material, the plastic composition material of the present invention has most of properties of common plastics. The material can be strong like other polyolefin materials. Containers for liquid made from plastic composition material may be relatively large, at least 2-liters in volume. The material can be very flexible. A container made from the material can be rolled or folded into small configuration. The material can have good heat-sealing properties and can be used in high speed heat-sealing packaging system. The material is an excellent barrier for liquid and gas, so a container made from the material can provide a long shelf life for the contents in the container. The material is safe and compatible with most foods or medicines and many other products. The material has excellent printability. Unlike common plastics, the material has very good cold and heat resistance properties The material is opaque. The plastic composition material has shown excellent heat conductivity which makes it suitable for a container used for products that are to be consumed in a heated condition, such as pap for babies. A filled container can thus conveniently be heated in the microwave oven or a hot water bath, and then be used as a baby bottle. It can have high stiffness if necessary.[0046]
To achieve a greater benefit from a mineral based filler/binder mixture, the mineral based filler content should be above about 30%. The mineral based filler content should not be too high, i.e. less than 90%, otherwise the filler/binder mixture may be brittle and relatively easily breakable upon impact, like egg shells. The amount of mineral based filler material content in the resulting plastic composition material is preferably in the range of 30-70%. The range of about 50-60% of mineral based filler material in the resulting mixture is more optimal. The most desirable plastic composition material is to have about 55% mineral based material and about 45% polyolefin. When calcium carbonate is the mineral based filler material, calcium carbonate content is preferably in the range of about 50% to about 70%, with the remainder being primarily polyolefins or other suitable plastic material.[0047]
The plastic composition material is commercially available from Ecolean, under the trademark LeanMaterial.[0048]
While preferred embodiments of the invention have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.[0049]