CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation of prior U.S. application Ser. No. 10/376,350, filed Feb. 27, 2003, which is a continuation of U.S. application Ser. No. 09/993,546, now U.S. Pat. No. 6,951,696, filed Nov. 27, 2001, which is a continuation of U.S. application Ser. No. 09/741,785, now U.S. Pat. No. 6,290,124, filed Dec. 19, 2000, which is a continuation of U.S. application Ser. No. 09/260,854, now U.S. Pat. No. 6,196,452, filed Mar. 1, 1999, which is a continuation of U.S. application Ser. No. 08/926,520, now U.S. Pat. No. 5,909,841, filed Sep. 10, 1997, which is a continuation of U.S. application Ser. No. 08/645,218, now U.S. Pat. No. 5,715,992, filed May 13, 1996, which claims the benefit of U.S. Provisional Application No. 60/004,298 filed Sep. 26, 1995.
FIELD OF THE INVENTION This invention relates to an improved beverage container. More specifically, this invention is directed to an improved container for storing and transporting several cups of fluid, such as coffee.
BACKGROUND AND SUMMARY OF THE INVENTION Gourmet coffee shops typically sell individual cups of coffee for consumption on or off the premises. Typically, these shops are very small and utilize high-quality coffee beans and coffee-making equipment to provide consumers with a higher quality cup of coffee than would be available in other establishments. In this regard, many gourmet coffee shops have developed internal procedures particularly adapted to ensure a uniformly high-quality cup of coffee. Particularly at peak periods, these shops must dispense coffee to a relatively large group of consumers in a short amount of time. Typically, the worker holds the coffee cup below the spout and utilizes the other hand to actuate the spout until the worker sees that the coffee cup is nearly full.
Consumers accustomed to the high-quality of coffee available from such gourmet coffee shops have come to desire this high level of quality at other locations, such as offices or meeting places. Gourmet coffee shops have met this need by providing thermos canisters which are loaned out and then returned by the consumer. These canisters are often elongate, cylindrical thermoses having a pump button in the top, which dispenses coffee from a nozzle. Unfortunately, the inconvenience of needing to return the canister and the typical requirement that a deposit be left deters consumers from purchasing larger quantities of coffee. These canisters also have several drawbacks for the coffee shop. Specifically, they are relatively large and difficult to store, are breakable and require careful cleaning after use.
Applicant's invention is an improved liquid container particularly adapted to store and insulate multiple cups of fluid. The invention includes numerous aspects. Advantageously, the preferred container is particularly adapted to be stored in a flattened state, while at the same time being quickly and easily deployable. Importantly, the container can desirably be filled with existing equipment utilizing the existing procedures utilized in most coffee shops. The container is also desirably particularly adapted to be easily carried and poured. Advantageously, the structure of the container reduces the likelihood that the container will tip over during transport and incorporates safety features which reduce the risk of injury to the user from hot coffee. Importantly, the container is also structured to reduce the risk of damage to furniture resulting from the temperature of the fluid in the container. Because the container is particularly adapted to be made of very inexpensive materials, the container need not be returned nor cleaned.
One aspect of the invention is a container including an outer shell, a flexible bag within the outer shell, a mouth and a handle. The outer shell has a top, a bottom and sidewalls. The outer shell also defines an opening. The flexible bag within the outer shell defines an aperture. The mouth is secured to the flexible bag surrounding the aperture and defines a fluid passageway. The mouth is sized and shaped such that fluid can be poured through the mouth from a source having an outlet spaced above the mouth. The handle extends outward from the top of the outer shell and has sufficient strength to provide essentially all support for the container when the bag is filled with liquid in either of two positions, with the first position being where the opening is facing upwards and the second position being where opening is facing sidewards.
Desirably, the mouth and opening are sized and shaped such that when the opening is facing upwards the human eye can detect when a level of fluid in the container is approaching the mouth. Advantageously, the mouth defines an aperture having a span of at least one inch.
In another aspect, the outer shell has a lower panel upon which the bag rests when it is filled with liquid which is spaced at least one-quarter and, preferably, one-half inch above bottom of the outer shell.
In another aspect, the bag and the outer shell are sized and shaped such that when the bag is substantially full of liquid, the center of gravity of the container is located at least one-half inch and, preferably, at least one inch, below the vertical center of the container.
Yet another aspect of the invention is a foldable liquid container, including an outer shell and a bag within the outer shell which defines an aperture. The outer shell comprises a first pair of sidewalls aligned generally in the same plane as one another and a second pair of sidewalls aligned generally in the same plane as one another. The outer shell further includes a plurality of upper end flaps secured to the first pair of sidewalls and the second pair of sidewalls. Desirably, at least one of the upper end flaps forms at least a portion of a handle when the container is folded and a plurality of lower end flaps secured to the first pair of sidewalls and the second pair of sidewalls. The outer shell also defines an opening in one of the pairs of sidewalls. The mouth is secured to the flexible bag surrounding the aperture and defines a fluid passageway. The mouth is sized and shaped such that fluid can be poured through the mouth from a source having an outlet spaced above the mouth.
Another aspect of the invention is a liquid container including an outer shell having a top and a bottom, the outer shell having an opening on a side of the container, a flexible bag within the outer shell, a mouth secured to the flexible bag surrounding the aperture and defining a fluid passageway and a handle extending from the top of the outer shell, the bag sized and shaped such that when the bag is filled with a fluid to a first level proximate the mouth when the mouth is facing upwards and the container is rotated to rest on the bottom, the fluid assumes a second level below the mouth. Desirably, the bag and the outer shell are sized and shaped such that when the bag is substantially full of liquid, the center of gravity of the container is located at least one inch below the center of the container.
Desirably, the bag is sized smaller than the outer shell so that when the container is rotated after filling to have the handle facing upwards and the spout facing the side, the bag sags downward within the outer shell, setting the level of fluid in the bag below the bottom of the spout. By ensuring that the level of fluid is below the spout, the present invention prevents accidental spillage of hot fluid during transport or handling of the container. Advantageously, the top side of the container ramps upward in an incline from the back side panel to the front side panel with the opening for the spout. Such a design facilitates dispensing fluid from the container when a user grips the handle and rotates the container forward to raise the level of the fluid to the spout. Other aspects of the invention include an improved liquid container for chilling fluid and an improved liquid container for storing and mixing dried flavor crystals with liquid.
An advantage of the present invention is that it can be stored flat and stacked in piles, thereby conserving large amounts of space in stores that sell coffee to go. Further, the container can be quickly folded together by using the fold-over flaps to assemble the top and bottom sides of the cardboard container.
Another aspect of the invention is a method of using a collapsed liquid container including (1) folding the container so that the container defines a top from which a handle extends, a bottom and a mouth defining a fluid flow path communicating with an interior of the container through a sidewall; (2) placing the container in a first position with the sidewall facing upward; (3) pouring fluid through the mouth into the container to at least partially fill the container with fluid; (4) sealing the mouth after the pouring of fluid into the container; and (5) manually grasping the handle to move the container after the sealing.
In its preferred embodiment, the present invention overcomes a variety of key problems in the prior art since it provides an easily deployable, inexpensive yet safe means for carrying, insulating, storing and dispensing hot fluids which conserves storage space and can be disposed of after use.
BRIEF DESCRIPTION OF THE DRAWINGS The preferred embodiments of this invention, illustrating its features, will now be discussed in detail. The drawings depict a preferred beverage container for illustrative purposes only. These drawings include the following figures, with like numerals indicating like parts:
FIG. 1 is a perspective view of the beverage container of the present invention.
FIG. 2 is a top plan view of a blank from which the outer shell of the present invention is manufactured.
FIGS. 3a-dare perspective views illustrating the formation of the bottom of the beverage container of the present invention.
FIGS. 4a-fare perspective views illustrating the formation of the top of the beverage container of the present invention.
FIGS. 5a-bare cross-sectional front views illustrating the filling of the bag of the beverage container of the present invention.
FIG. 5cis a cross-sectional side view illustrating the container of the present invention rotated 90° with respect to theFIGS. 5a-b.
FIG. 6 is a perspective view of several beverage containers of the present invention stacked in collapsed form.
FIG. 7 is a perspective view of the bag and mouth of the container ofFIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTFIG. 1 illustrates a perspective view of apreferred beverage container10 in its assembled form. Referring toFIGS. 1-6, thecontainer10 includes an outer container orshell3, aninner bag5, amouth7 and aspout9. Thebag5 is positioned within theouter shell3 and communicates with the exterior of thecontainer10 by means of themouth7 andspout9. Thecontainer10 has a front13, a back15, aleft side17, aright side19, a top21 and a bottom23. In addition, the container advantageously defines ahandle25.
As seen inFIG. 2, theouter shell3 is advantageously configured to be constructed from a single one-piece cardboard blank. The shell has afront wall panel16, aback wall panel18, a rightside wall panel20, a leftside wall panel22 and aside attachment tab66. Thefront wall panel16 defines acircular opening48 and taperedslits49. Thefront wall panel16 is hingedly attached along a rightfront fold line68 to rightside wall panel20. Opposite the rightfront fold line68, theright side panel20 is hingedly attached to theback wall panel18 along a right back rightback fold line70. The right wall panel further defines alower slot57. Opposite the right back foldline70, theback wall panel18 is hingedly attached to theleft wall panel22 along a leftback fold line72. Opposite the leftback fold line72, the attachment tab is attached to theleft wall panel22 along a leftfront fold line90.
The blank further incorporates a series of top flaps and a series of bottom flaps. The top flaps include a topfront flap40, a topright handle flap28, atop back flap42 and a topleft handle flap30. The bottom flaps include afront bottom flap54,right bottom flap56, aback bottom flap52 and aleft bottom flap50. Thefront wall panel16 is hingedly secured along a topfront fold line74 to the topfront flap40, and also hingedly secured along a double bottomfront fold line82 to abottom front flap54. The double fold line facilitates the folding of the blank against itself along the double fold line, as is well-known in the art. Theopening48 is defined within thefront wall panel16 in close proximity to the topfront fold line74. The topfront flap40 defines an open-endedslot44 extending to a distal edge of topfront flap40. Thefront wall panel16 and bottomfront flap54 cooperate to define afront air aperture61 along the bottomfront fold line82.
Theright side panel20 is hingedly coupled along a topright fold line76 to topright handle flap28 and is also hingedly secured along a double bottomright fold line84 to a bottomright flap56. The topright handle flap28 includes aright handle portion36 and aright tab portion32. The bottomright flap56 defines a small, generally semi-circular slit63 which forms afinger flap63. The bottomright flap56 also defines atab60 extending from a distal edge of the bottomright flap56.
The backside wall panel18 is hingedly secured along a topback fold line78 to the top backflap42 and also hingedly secured along a double bottomback fold line86 to the bottom backflap52. Theback wall panel18 andbottom back flap55 cooperate to define aback air aperture73 along the bottom back foldline86. The top backflap42 includes aclosed slot46 and a generally U-shapeddistal locking portion43. The left side wall panel is hingedly secured along a topleft fold line80 to the topleft handle flap30 and hingedly secured along a double bottomleft fold line88 to the bottomleft flap50.
The topleft handle flap30 includes a doubleleft handle portion38 and a pair ofleft tab portions34 which are formed by cutouts to define an opening underneath theleft handle portion38. Each of the bottom flaps50,52,54 and56 further defines aspacer fold line64 approximately one-half inch from itsrespective wall panel22,18,16 and20. Directly above thefold line64 on the bottomleft flap50 is aslot58 sized for receiving thetab60 of bottomright flap56 when the container11 is assembled. Thefold line64 along bottomleft flap50 further defines aleft spacer strip65 of the bottomleft flap50 that is defined by theparallel fold lines64 and82. The bottomleft flap50 defines a small, generally semi-circular slit75 which forms afinger flap77. The bottomleft flap50 also defines atab79 extending from a distal edge of the bottomright flap50.
Advantageously, prior to connecting theside tab66, extending from theleft side panel22 to thefront side wall16, thebag5 is connected to theouter shell3. In the preferred embodiment, thebag5 comprises several layers, having an inside taste-neutral layer that imparts no flavor, a middle layer that insulates the heat of the liquid, and an outer layer for providing strength and flexibility. Such bags are available from Scholle Corporation, having a manufacturing facility in Rancho Dominguez, Calif. Desirably, the bag can be constructed from flat sheets, which are heat sealed and cut to form the desired shape. Referring toFIG. 7, in the preferred embodiment, thebag5 is generally 13½ inches by 13½ inches, sealed along its entire perimeter and has vertically oriented dart seals90 (as shown inFIG. 7) which form isoceles triangle shaped cutouts having equal sides of 4 inches along the perimeter of thebag5 at the corners on either side of themouth7. Themouth7 has a generally cylindrical body92 with an annularouter rim94 at one end which is bonded to thebag5 by an appropriate adhesive or other means known in the art, andexternal threads96 at the other end. The body92 is desirably provided with a of raised annular ring spaced slightly from theouter rim94 which forms an annular groove. The body92 of themouth7 further defines a generally cylindricalinternal channel100. Themouth7 is advantageously sized and shaped for theexternal threads96 and raised annular ring to be slightly larger than theopening48 in thefront wall panel16 of theouter shell3. Theslits49 in thefront wall panel16 facilitate the their insertion through theopening48. Thus positioned, the mouth is secured within theouter shell3 by theouter rim94. Thebag5 may also be more securely retained in position within theouter shell3 by means of adhesive between therim94 and the interior of thefront wall panel16 surrounding theopening48. Thebag5 is desirably inserted into theouter shell3 with its cutout corners and the corner opposite the mouth folded up and inward toward the center of the bag.
Referring toFIGS. 4 and 5, thespout9 of the container will now be described. The spout is desirably conical in shape and is internally threaded to mate with themouth7. For convenience, the mouth may include a tear-off portion for sealing the container, until the destination is reached.
Thetab66 of the leftside wall panel22 is fastened to the frontside wall panel16 along anedge17 of thefront side wall16 opposite of the rightfront fold line68. The fastening may be accomplished by double sided adhesive, glue or other fastening means known to those of skill in the art. Upon fastening, theouter shell3 may then be laid and stored flattened with two adjacent side wall panels,panels16 and20 for example, facing upwards, and the other two side wall panels,panels18 and22, facing downwards. The outer shell is thus ready for quick assembly and may be stored efficiently in stacks as illustrated inFIG. 6. Advantageously, thespout9 is threaded onto the mouth after the container has been filled.
The assembly of thecontainer10 will now be described.FIGS. 3a-dillustrates the assembly of the bottom of theouter shell3.FIG. 3ashows thecontainer10 turned over so that the bottom flaps50,52,54, and56 are facing upwards and theside wall panels16,18,20, and22, folded to form a substantiallyrectangular opening55. In this position, the frontside wall panel16 is folded along leftfront fold line90 so that the front side wall panel is perpendicular to the leftside wall panel22. Thefront wall panel16 is also oriented perpendicularly with respect to rightside wall panel20 along rightfront fold line68, so that leftside wall panel22 and rightside wall panel20 are parallel to each other. Theback wall panel18 is folded along the leftback fold line72 to be perpendicular to the leftside wall panel22, and is also folded along the right back foldline70 to be perpendicular to the rightside wall panel20. Theback wall panel18 is thus parallel to thefront wall panel16.
FIG. 3aindicates that the bottomleft flap50, which is secured to the left side wall panel along bottomleft fold line88, is the first flap that is folded over and is folded along the bottomfront fold line88 into theopening55. When the bottomleft flap50 is turned over, theleft spacer strip65 is folded down against the interior of leftside wall panel22, thetab79 extends throughslot57 in theright side panel20 and the distal edge of the bottomleft flap50 contacts the interior of rightside wall panel20 as shown inFIG. 3b. The bottomleft flap50, with the exception of thespacer strip65 is thus oriented perpendicularly to thewall panels16,18,20, and22, and is recessed below the bottomleft fold line88.
FIGS. 3band3cindicate that the bottom backflap52 and bottomfront flap54, which are secured to theback wall panel18 and thefront wall panel16, respectively, are then folded over on top of the bottomleft flap50 about their respectivebottom fold lines86 and82. As with the bottomleft flap50, theback spacer strip67 of the bottom backflap52 and thefront spacer strip69 of thebottom front flap54 are folded down along thefold line64 against the interior of theback wall panel18 and the interior of thefront wall panel16, respectively. When the bottom flaps52 and54 are folded over onto bottomleft flap50, theedge51 of the bottom backflap52 meets with theedge53 of thebottom front flap54 to create a second layer of cardboard on top of the first layer, the bottomleft flap50.
FIGS. 3cand3dillustrate that the bottomright flap56 is the last bottom flap to be folded over to create the bottom of theouter shell3. When the bottomright flap56 is folded over, theright spacer strip71 of the bottomright flap56 is folded down along thefold line64 against the interior of theright side wall20. Thebottom flap60 is then folded over onto the bottom flaps52 and54, thereby creating a third recessed cardboard layer. Thetab60 of the bottomright flap56 is inserted onto theslot58 of the bottomleft flap50 to secure the bottom flaps50,52,54, and56 in place. Thus assembled, thefront air aperture61 and theback air aperture73 form air vents to permit the circulation of air under the bottomright flap56. To remove the bottom flaps from the secured position shown inFIG. 3d, a user may pull the bottom flap out of its secured position by using thefinger flap63 of thebottom flap60 or the opening formed by pushing thefinger flap63 inward.
FIGS. 4a-4fillustrate the formation of the top and handle25 of theouter shell3 of the present invention.FIGS. 4aand4bindicate that the topright handle flap28, which is secured to rightside wall panel20 along topright fold line76, is folded over into opening41 in the top so that the topright handle flap28 is in alignment with the topright fold line76.FIG. 4billustrates thatright handle portion36 is then folded upward from the topright handle flap28 so that theright handle portion36 is perpendicular to the topright handle flap28.
FIG. 4cshows that the topleft handle flap30 is then folded down and theleft handle portion38, which is also folded upright like theright handle portion36, cooperates withright handle portion36. Thetab34, which is cutout from underneath theleft handle portion38 is placed through the opening underneath theright handle portion36 and over theright tab32. As shown inFIG. 4d, theleft handle portion38 is then folded over theright handle portion36 and thedistal tab34 of theleft handle portion38 is slid under theproximal tab34 of the left handle portion to form the handle26 of theouter shell3.FIG. 4eshows topfront flap40 folded over along topfront fold line74 onto the topright handle flap28 and the topleft handle flap30. The handle26 is inserted through the open-endedslot44, thereby allowing the topfront flap40 to rest flat against the right and left handle flaps28 and30. As shown inFIG. 4f, the top backflap42 is folded over along topback fold line78 onto the topfront flap40 and the top right and left handle flaps28 and30. The handle26 is inserted through theslot44 of the top backflap42, allowing the top backflap42 to rest flat against the topfront flap40 and the top right and left handle flaps28 and30. Thedistal locking portion43 of the top backflap42 is inserted into the groove formed by the body92 of the mouth so that the locking portion prevents the mouth from being pulled back into theouter shell3 by the weight of the liquid when filled. The topfront flap40 and the top backflap42 lock the handle flaps28 and30 in place. Thus assembled, thehandle25 defines a first end proximate thefront wall panel16 and a second end spaced further from the front wall panel than the first end, and the handle defines an opening between first end and the second end sized and shaped to receive the fingers of a hand.
Desirably, thefront13 of theouter shell3 has a vertical height of roughly 8½ inches and a width of roughly 6⅛ inches. The bottom23 has a width of roughly 6⅛ inches and a length of roughly 8½ inches. Theback15 of the outer shell has a height of roughly 6 inches and a width of roughly 6¼ inches.
FIGS. 5aand5billustrate the filling of thecontainer10 of the present invention.FIG. 5ais a schematic view illlustrating the compressed,flexible bag5 located within theouter shell3 and the container in the “fill” position—namely, held in the right hand of the user with thecontainer10 resting on its backside wall panel18 with the frontside wall panel16 facing upwards. The left hand of the user actuates the spigot from the pot.FIG. 5billustrates coffee being poured into thebag5 through themouth7 from a spigot spaced over themouth7, thereby forcing the bag to expand. To maximize the volume of liquid that thebeverage container10 may hold, thebag5 is sized and shaped so that it may expand into the corners of theouter shell3. Advantageously, the container has a capacity of at least 48 ounces of fluid, desirably, between 70 and 200 ounces of fluid and, most desirably, roughly 96 ounces of fluid.
Since themouth7 desirably defines a flow channel having a diameter of at least ¾ inches, desirably at least one inch and most desirably 1¼ inches, the user is able to visually determine when the level of fluid in the bag is proximate the bottom of themouth7 and moves the spigot to cut off the flow of fluid into thecontainer10. Thebag5 is desirably sized such that when the level of fluid in the container is proximate the bottom of themouth7 when the container is positioned with itsback wall panel18 faced downward and in a horizontal orientation, when thecontainer10 is rotated to rest on its bottom23 with the handle26 facing up, the level of fluid in thebag5 is below any opening formed by thespout9 and, desirably, below theinternal flow channel100 of themouth7. This reduces the risk of spilling during transport and the risk of injury to the user from spillage of hot coffee when the spout is opened. Effectively, thebag5 to “sags” within theouter shell3 when the container is rotated from its fill position to its “carry” position so that the level of fluid is below the level of the mouth. The volume of fluid in the container when the container is in its fill position and the level of fluid in the container is proximate the bottom of themouth7, is referred to as the “normal fill volume.”
An important aspect of the invention is that theflaps40 and42 provide the advantage of minimizing the load on the handle26 by transferring the a portion of the load from the weight of thecontainer10 and the contents from the handle26 across theflaps40 and42. With thehandle25 secured in place, thecontainer10 may be easily transported and carried like a briefcase. The carrier thus avoids having to hold theouter shell3 which may be hot from the coffee or other liquid inside by the wall panels.
Yet another important advantage of the invention is that when the container is filled to its normal fill volume and positioned with its bottom facing downward and in a horizontal orientation, the center of gravity CG of the filled container is located at least one-half inch below the vertical center of the container VC (i.e., half-way between the top and bottom of the outer shell) and, preferrably, at least one inches below the center of gravity of the container. This is important to reduce the risk that the container will tip over during transport. In addition, the cross-sectional area of the bottom of theouter shell3 is desirably as large as any horizontal cross-section of the container to further reduce the risk that the container will tip over when transporting or manipulating the container.
Advantageously, the top of theouter shell3 ramps upward from the backside wall panel18 to the frontside wall panel16, which has theopening48 for a spout. This preferred design facilitates dispensing fluids from the container when a user grips the handle26 and rotates thecontainer10 forward to pour the fluid within the container out of thespout9. Specifically, the amount the user needs to pivot their hand relative the arm to pour is reduced, because the fluid in the container is already tipped toward the spout when the handle is horizontal from the rest position (with the bottom supported on a horizontal surface).
Importantly, by having the bottom of theouter shell3 configured as shown inFIG. 3dwith a recessed bottom, only the thin edges formed by thebottom fold lines82,84,86 and88 contact a support surface when theouter shell3 is set on in its bottom23. Because the bottom flaps50,52,54, and56, are recessed from the bottom23 of the container, heat is not transfered directly from the bottom flaps to the support surface. The transfer of heat is further reduced by the air vents formed at the front and back of the container. Furthermore, the present invention provides multiple layers of cardboard in bottom flaps50,52,54, and56, thereby providing extra insulation from the heat. All of this is possible in alow cost container10 particularly adapted to be constructed of such low cost materials that it can be disposable.
Thecontainer10 is also particularly adapted to be used to mix hot and cold flavored drinks, by means of storing the flavor crystals in thebags5 of a flattened container until it is desired to add liquid thereto. In this case, thechannel100 of themouth7 is desirably sealed by thespout9 or other means, such as a removable aluminum cover.
Finally, thecontainer10 is also particularly adapted to be used to heat or cool liquids by placing a source of heat or a cold pack or ice in theouter shell3 before closing either the top flaps or the bottom flaps of the outer shell. Alternatively, it is possible to insert ice through themouth7 into thebag5, to chill fluid therein.
Those of skill in the art will recognize that there are numerous variations and modifications of this invention which are encompassed by its scope. Accordingly, the foregoing description should be considered illustrative of the invention and not deemed to limit its scope.