Patent Grant
10870505
Bingham plastics are a class of materials that exhibit little or no deformation up until a certain yield stress is reached. Examples of Bingham plastics are toothpaste, ketchup, margarine, mayonnaise, uncured cement, uncured concrete, bitumen, grease, some molten polymers, and some paints. Because Bingham plastics behave as solids under no or low shear stress, and do not readily flow, they can be difficult to dispense. As a result, manufacturers are constrained to a limited set of container designs and materials for packaging Bingham plastics. There is a need for containers with surfaces that promote and/or ease the dispensing of Bingham plastics. In particular, there is a need for containers with interior surfaces that facilitate the removal of Bingham plastic products without contamination or adulteration of the Bingham plastic products.
Embodiments described herein relate generally to containers with liquid films on one or more surfaces thereof, and methods for applying such films. Specifically, the present disclosure relates to containers having liquid films on their interior surfaces and configured to hold Bingham plastic materials. For example, containers of the present disclosure are designed for packaging, surrounding, wrapping, encasing, encapsulating, or otherwise containing products that are Bingham plastic materials. In some embodiments, a container for containing a product includes an interior surface and a liquid disposed on the interior surface. In some embodiments, the liquid has a contact angle, θos(a), equal to 0°, and has a contact angle, θos(p), of between about 0° and about 60°, between about 1° and about 60°, between about 5° and about 50°, between about 5° and about 40°, between about 5° and about 30°, between about 0° and about 30°, between about 1° and about 30°, between about 1° and about 40°, between about 1° and 50°, or about 60°, where “o” denotes the liquid, “s” denotes the interior surface, “a” denotes air, and “p” denotes a product. In some embodiments, the product is a Bingham plastic material that behaves as a solid below a certain threshold of shear stress (e.g. from an external for or by gravity), known as the yield stress of the Bingham plastic. Above the yield stress, a Bingham plastic behaves, or “flows,” like a liquid.
Bingham plastics are a class of materials that exhibit little or no deformation up until a certain yield stress is reached, at which point, they begin to flow. They behave as solids under no or low shear stress, and as viscous liquids when an applied shear stress exceeds a yield stress. Specifically, for purposes of the instant disclosure, a “Bingham plastic” refers to any material that does not substantially deform plastically (or “flow) until a yield stress is reached. Unlike many liquids that readily flow from containers, Bingham plastics typically require an applied force to initiate dispensing (i.e., once the applied shear stress is greater than the yield stress, viscous flow begins). Examples of Bingham plastics include toothpaste, ketchup, margarine, mayonnaise, uncured cement, uncured concrete, bitumen, grease, some molten polymers, and some paints.
Because Bingham plastics behave as solids under no or low shear stress, and do not readily flow, they can be difficult to dispense. Consumers waste billions of dollars worth of product each year due to the fact that many consumer products, including Bingham plastics, adhere to their containers and are difficult to remove. This limits manufacturers' ability to use certain container designs and materials. For example, manufacturers often employ deformable containers whereby the consumer squeezes the walls of the container to apply a stress to the Bingham plastic and initiate viscous flow. Manufacturers typically select materials that are capable of being repeatedly deformed so that the consumer can apply a force onto the Bingham plastic product. Manufacturers may also reduce the viscosity of the Bingham plastic product to facilitate dispensing. This means that there is proportionately less of the active ingredient(s) in the product, due to the presence of viscosity modifiers or solvents, than there would be without the need for such additives. As an alternative approach, some manufactures use rigid containers with large openings which require a user to directly access the Bingham plastic product and to manually remove it. These types of rigid containers have drawbacks such as requiring additional tools to remove the product, limited container design choices, and increased manufacturing costs. Small-mouthed, rigid containers often require the user to shake the container to apply an inertial force to the Bingham plastic product to initiate flow. Shaking the container can result in the product being incorrectly applied in the amount and/or location, strain on the consumer, and container breakage.
Another problem with dispensing Bingham plastic materials is that they are prone to stick or otherwise adhere to the inner walls of the container. Unlike many liquids which will eventually flow back and settle to the bottom of a container under the force of gravity, Bingham plastic materials often adhere to walls and do not flow until subjected to at least a minimum yield stress. In some container configurations, it is difficult or impossible for a user to practically apply the requisite yield stress to portions of product that are stuck to inner walls of a container, for example when a majority of the product has been removed. This frequently results in wasted product that is ultimately discarded along with the container.
Applying embodiments described herein to consumer containers and packaging can eliminate waste since nearly 100% of the product can be evacuated (i.e., removed, dispensed, and/or the like) from the container, making the production, consumption, and disposal of the product and its packaging more environmentally friendly. In some embodiments, coated containers described herein allow for the use of higher concentration consumer product formulations, with higher viscosities, than was previously possible. Manufacturers using coatings and/or coated containers according to the present disclosure will have greater flexibility when innovating their product formulations. For example, products can be made thicker, and can be made at higher concentrations (e.g., through elimination of the need for additives such as solvents or water), allowing for the size of the packaging to shrink without sacrificing value to the consumer. Smaller packaging also means that more containers fit in a fixed shipment volume, resulting in lower transport costs and fuel emissions since fewer shipments are necessary. Additional advantages include the elimination of the need for bulky squeeze caps and pump systems that are commonly used for dispensing consumer products from containers. Eliminating these expensive caps and dispensers can reduce packaging costs and eliminate millions of tons of petroleum-based plastics from ending up in landfills each year Embodiments described herein can also result in significant cost saving benefits for manufacturing processes. For example, less product adhesion along product delivery lines and piping results in fewer and/or less frequent cleaning cycles, and allows for increased production. As a result, less product waste is generated during the production process, saving resources and making the process and the company more environmentally friendly.
In some embodiments, a container for containing a product includes an interior surface and a liquid disposed on the interior surface. When disposed on the interior surface of the container, the liquid exhibits a “contact angle,” e.g., with respect to the interior surface on which it is disposed. The contact angle may vary depending upon the properties of one or more “phases” (e.g., solid, semi-solid, immiscible liquid, gas, etc.) adjacent to the liquid. Contact angles are hereinafter referred to using the symbol “θ,” with subscripts identifying the materials forming the interface and adjacent phase at which point the contact angle is measured. The subscript “o” denotes liquid, subscript “s” denotes the interior surface, subscript “a” denotes air, and subscript “p” denotes a product. In some embodiments of the present disclosure, a liquid-air interface has a contact angle θos(a) of 0° (e.g., a “fully wetted” state), and a liquid-product interface also has a contact angle θos(p), of 0°. Contact angle θos(p) refers the angle made between a solid-liquid and liquid-product interface in a system where a solid is intercepted by the liquid-product interface. In some embodiments of the present disclosure, a liquid-air interface has a contact angle θos(a) of 0° (e.g., a “fully wetted” state), and a liquid-product interface also has a contact angle θos(p), of between about 0° and about 60°, between about 1° and about 60°, between about 5° and about 50°, between about 5° and about 40°, between about 5° and about 30°, between about 0° and about 30°, between about 1° and about 30°, between about 1° and about 40°, or between about 1° and 50°. In one embodiment, the liquid-air interface in contact with an interior surface of the container has a contact angle, θos(a), with respect to the interior surface of the container, of between 0° and 5°, and once a product has been introduced, a liquid-product interface in contact with an interior surface of the container makes a contact angle θos(p), with respect to the interior surface of the container, of between about 0° and about 60°, between about 1° and about 60°, between about 5° and about 50°, between about 5° and about 40°, between about 5° and about 30°, between about 0° and about 30°, between about 1° and about 30°, between about 1° and about 40°, or between about 1° and 50°. In some embodiments, a container for containing a product includes an interior surface and a liquid having a density disposed on the surface. A product, having a density, is disposed within the container. In some embodiments, the density of the product is about equal to (e.g., +/−10% of) the density of the liquid, the liquid-air interface makes a contact angle, θos(a), with respect to the interior surface of the container, equal to about 0°, and once a product has been introduced, a liquid-product interface in contact with the interior surface of the container makes a contact angle, θos(p), with respect to the interior surface of the container, of between about 0° and about 60°, or between about 0° and about 50°, or between about 1° and about 40°, or between about 0° and about 30°, or of less than or equal to 30°.
In some embodiments, a method of manufacturing a packaged product includes disposing a liquid onto an interior surface of a container and transferring a product into the container. In some such embodiments, the liquid is introduced into the container first, and the product is subsequently introduced into the container. In other embodiments, the liquid and product are provided to the container simultaneously, and the liquid is first in contact with the product, and subsequently in contact with the container. In some such embodiments, a liquid-air interface in contact with the interior surface of the container makes a contact angle, θos(a), with respect to the interior surface, of about 0°, and a liquid-product interface in contact with an interior surface of the container, makes a contact angle, θos(p), with respect to the interior surface, of between about 0° and about 30°. In still further embodiments, the liquid is applied to the product first, and then the liquid-coated product is subsequently introduced into the container.
In some embodiments, an apparatus for storing a flowable product includes a container having an interior surface (e.g., one or more walls) that defines an inner volume. A liquid, having a first density, is disposed on at least a portion of the interior surface of the container, such that a contact angle, θos(a), made by a liquid-air interface in contact with the interior surface of the container, equals about 0°. In some such embodiments, the container also includes a product (having, for example, a second density approximately equal to the first density) disposed within the inner volume of the container, and a contact angle, θos(p), made by a liquid-product interface in contact with the interior surface, is less than about 30° (e.g., between about 0° and about 30°). As described hereinbefore, the subscript letter “o” denotes the liquid, subscript “s” denotes the interior surface, subscript “a” denotes air, and subscript “p” denotes a product.
As used herein, the term “about” or “approximately” generally means plus or minus 10% of the value stated. For example, “about 5” would include 4.5 to 5.5, “about 10” would include 9 to 11, and “about 100” would include 90 to 110.
In some embodiments, a product to-be-contained (e.g., a Bingham plastic product) itself coated with a liquid as it is being transferred to the container 110 (e.g., by way of a nozzle, funnel, pipe, tube, and/or other suitable delivery device, and/or the like), resulting in the container having the liquid disposed on its interior surface and containing the product in the inner volume 151. In other words, the act of transferring the product into the inner volume of the container causes the liquid to become disposed on the interior surface of the container. In such embodiments, the product may be said to be a “carrier” for the liquid, transporting it into the inner volume of the container as it is dispensed. The act of transferring the product into the inner volume of the container, e.g. at 141, may thus be said to occur prior to or concurrently with disposing the liquid onto the interior surface of the container, e.g., at 131). At the end of such processes, the liquid that first coated the product may be said to also “coat” the interior surface of the container, since the liquid coating carried by coated product makes contact with at least a portion of the container wall(s) and forms an interface (i.e., a liquid surface film) between the contained product and the container wall(s).
In some embodiments, a method of manufacturing a packaged product 100 comprises at step 131, disposing a liquid onto the interior surface of the container, substantially concurrently with the step 141 of transferring a product (e.g., a Bingham plastic product) into the inner volume of the container, for example during introduction of said product into container 110 (e.g., by way of a coaxial nozzle, an extrusion tool, and/or a combination of pipe, tube, spray, and/or other suitable delivery mechanisms in simultaneous operation, and/or the like), resulting in a container with liquid disposed on its interior surface and containing the product in the inner volume 151. In such embodiments, for example, the liquid may be dispensed into the container around the edges of an opening therein, while the product is dispensed at or near the center of said opening. As such, as the liquid may “wet” the interior surface (e.g., the walls) of the container as it is being filled, and as the product fills the inner volume of the container, it comes into contact with the liquid-coated interior surfaces. In some embodiments involving substantially concurrent dispensing of the liquid and the product, the dispensing of the liquid may commence slightly prior to the dispensing of the product, to ensure full coverage of the liquid on the interior surface of the container.
At the conclusion of any of the above-described exemplary methods, the finished product (i.e., a manufactured, packaged product) 151 collectively comprises the contained product, and container 110 with its interior surface coated with the liquid, the liquid providing a low surface energy boundary surrounding the product. The liquid prevents the product from adhering to the interior surfaces of the container 110, and facilitates complete or substantially complete discharge of the product.
The container 110 can be any suitable container for containing a Bingham plastic product. Examples of suitable containers include tithes, bottles, vials, flasks, molds, jars, tubs, bags, pouches, boxes, tins, capsules, cups, glasses, pitchers, barrels, bins, totes, tanks, kegs, tubs, syringes, tins, pouches, lined boxes, hoses, cylinders, and cans. The container 110 can be constructed in any desirable shape, as the container does not have the typical constraint of product being easily trapped in sharp corners or intricate detail. Furthermore, greater surface-to-volume ratio shapes than typical can work and still enable the product to flow. For example packaging shaped like animals, narrow rectangular shapes or prisms, spirals or tubes, Additionally, embodiments described herein can be applied to hoses, piping, conduit, nozzles, faucets, apertures, spray heads, syringe needles, dispensing tips, lids, pumps, and other surfaces for containing, transporting, and/or dispensing Bingham plastic products.
The container 110 can be constructed of any suitable material, including plastic, glass, metal, ceramic, composite, wood, coated fibers, and combinations thereof. Suitable surfaces can include, for example, polystyrene, nylon, polypropylene, wax, polyethylene terephthalate, polypropylene, polyethylene, polyurethane, polysulphone, polyethersulfone, polytetrafluoroethylene (PTFE), tetrafluoroethylene (TFE), fluorinated ethylenepropylene copolymer (FEP), polyvinylidene fluoride (PVDF), perfluoroalkoxytetrafluoroethylene copolymer (PFA), perfluoromethyl vinylether copolymer (MFA), ethylenechlorotrifluoroethylene copolymer (ECTFE), ethylene-tetrafluoroethylene copolymer (ETFE), perfluoropolyether, Tecnoflon cellulose acetate, and polycarbonate. The container 110 can be constructed of rigid and/or flexible materials, and in some embodiments may be “lined.” For example, foil-lined or polymer-lined cardboard or paper boxes can also form suitable containers. The container 110 can have an interior surface that is solid, compliant, smooth, textured, rough, and/or porous.
The liquid of the present disclosure can also be referred to as a lubricant. Suitable liquids include, for example, one or more of the following: vegetable oils, lipids, triglycerides, esters, terpenes, FDA approved food additives, a monoglyceride, a diglyceride, a triglyceride, a citric triglyceride, a fatty acid, an alcohol, a fatty acid alcohol, a wax, a fiber, cellulose, a ketone, an aldehyde, a protein, a sugar, a salt, a mineral, a vitamin, a carbonate, a ceramic material, an alkane, an alkene, an alkyne, an zacyle halide, a carboxylate, a carboxylic acid, a methoxy, a hydroperoxide, a peroxide, an ether, a hemiacetal, a hemiaketal, an acetal, a ketal, an orthoester, an orthocarbonate ester, and foods, for example, foods approved as food additives by the Japanese ministry of health labour and welfare, or other foods approved as food additives approved by other regulatory agencies in other countries, materials considered safe for use in their intended application (for example, an inactive drug ingredient would be suitably safe for use as the liquid coating for ointments or other drug products). The liquid should not react with the product in a way that negatively impacts the product. It is often desirable that the liquid is essentially flavorless or essentially odorless, but the liquid can also have flavors and odors, especially those which enhance the product. Suitable liquids can contain additives, for example including FDA approved drugs or inactive drug ingredients.
In some embodiments particles can be added to the liquid, such that the particles form the texture of a liquid-impregnated surface.
In some embodiments, the materials included in any of the liquid surface films described herein can be flavorless or have high flavor thresholds (e.g., containing one or more flavorants at a concentration below 500 ppm), and can be odorless or have a high odor threshold. In some embodiments, the materials included in any of the liquid surface films described herein can be substantially transparent. For example, the liquid and the container materials can be selected so that they have substantially the same or similar indices of refraction (this type of materials selection is sometimes referred to as “index matching”). When coated containers of the present disclosure are formed using index-matched materials, they may exhibit desirable optical properties, such as reduced light scattering and improved light transmission. For example, by utilizing materials that have similar indices of refraction and have a clear, transparent property, a surface having substantially transparent characteristics can be formed.
In some embodiments, the liquid can include an FDA approved health or beauty product, a flavor, a fragrance, and/or one or more additives. The additive can be configured, for example, to reduce the viscosity, vapor pressure, and/or solubility of the liquid. In some embodiments, the additive can be configured to increase the chemical stability of the liquid surface film once formed, for example the additive can be an anti-oxidant configured to inhibit oxidation of the liquid surface film. In some embodiments, the additive can be added to reduce or increase the freezing point of the liquid. In some embodiments, the additive can be configured to reduce the diffusivity of oxygen or CO2 through the liquid surface film, or enable the liquid surface film to absorb more ultra violet (UV) light, for example to protect the product (e.g., any of the products described herein) contained within a container on which the liquid surface film is disposed. In some embodiments, the additive can be configured to impart an intentional odor, for example a fragrance (e.g., smell of flowers, fruits, plants, freshness, scents, etc.), to the liquid surface film. In some embodiments, the additive can be configured to provide color to the liquid surface film and can include, for example, a dye or an FDA approved color additive. In some embodiments, the liquid surface film includes an additive that can be released (e.g., instantaneously upon contact with a product, or over time through controlled release) into the product, for example, a flavor or a preservative. Additives according to some embodiments of the present disclosure may be granular and “encapsulated” such that they do not contact, dissolve into, or other become incorporated in the product until they have been chemically and/or mechanically altered (e.g., slow dissolution of an encapsulate material over time through solubility with the product, and/or rupture through mechanical action).
In some embodiments, the liquid surface film includes a liquid having a melting point that is higher than the temperature at which the container bearing said liquid surface film would typically be stored, shipped, transported, etc. In other words, the liquid may be frozen during certain such periods. When the liquid surface film is solidified through freezing, it dissolves much more slowly (e.g., in the presence of an adjacent product), and to a lesser extent, thereby enhancing the lifetime of the liquid surface film during storage. Upon thawing, the liquid surface film regains the performance characteristics that it had prior to freezing (i.e., its “slippery” properties). This ability to freeze the liquid component of the liquid surface film may be desirable, for example, during periods of time when the liquid surface film has been applied to a container but the container does not yet contain a product, or when a product within a container coated with the liquid surface film does not yet need to be dispensed (e.g., during shipment or storage).
In some embodiments, the materials included in any of the liquid surface films described herein can be recyclable. For example, the liquid can comprise or include one or more materials that wash away during standard container (e.g., glass bottle, plastic bottle, etc.) recycling processes. For example, the liquid surface film can be configured to pass standard recycling tests provided by the Association for Postconsumer Plastic Recyclers (e.g., successful removal using the typical wash used in PET bottle recycling). In some embodiments, the liquid surface film can be configured to dissolve in a caustic wash, for example a solution of Triton X 100 or sodium hydroxide (NaOH) at high temperature, an acid wash, a solvent wash, or any other dissolving solution.
In some embodiments, any of the liquid surface films described herein can include, for example, preservatives, sweeteners, color additives, flavors, spices, flavor enhancers, fat replacers, and components of formulations used to replace fats, nutrients, emulsifiers, surfactants, bulking agents, cleansing agents, depilatories, stabilizers, emulsion stabilizers, thickeners, flavor or fragrance, an ingredient of a flavor or fragrance, binders, texturizers, humectants, pH control agents, acidulants, leavening agents, anti-caking agents, anti-dandruff agents, anti-microbial agents, anti-perspirants, anti-seborrheic agents, astringents, bleaching agents, denaturants, depilatories, emollients, foaming agents, hair conditioning agents, hair fixing agents, hair waving agents, absorbents, anti-corrosive agents, anti-foaming agents, anti-oxidants, anti-plaque agents, anti-static agents, binding agents, buffering agents, chelating agents, cosmetic colorants, deodorants, detangling agents, emulsifying agents, film formers, foam boosting agents, gel forming agents, hair dyeing agents, hair straightening agents, keratolytics, moisturizing agents, oral care agents, pearlescent agents, plasticizers, refatting agents, skin conditioning agents, smoothing agents, soothing agents, tonics, and/or UV filters.
In some embodiments, the liquid surface film can include materials having an average molecular weight in the range of about 100 g/mol to about 600 g/mol, which are included in the Springer Material Landolt-Bornstein database located at, “http:www.springermaterials.com/docs/index.html”, or in the MatNavi database located at “www.mits.nims.go.jp/index_en.html”. In some embodiments, the liquid can have a boiling point greater than about 150° C. or greater than about 250° C., such that it is not classified as a volatile organic compound (VOC). In some embodiments, a liquid surface film can include a liquid whose density is substantially equal to the density of the product to be contained within a container bearing the liquid surface film.
Typically, the liquid will have a viscosity of less than 1,000 cP, 100 cP, 50 cP, 20 cP, or 10 cP at room temperature, facilitating coverage of the liquid on a given surface. The liquid will also typically have a vapor pressure of less than or equal to the vapor pressure of water. Where a product is water-based, the liquid should be immiscible with water, or at least have an extremely low miscibility with water. Where a product is oil-based, the liquid should be immiscible in oil, or at least have extremely low miscibility in oil. Partial miscibility of the liquid with the product, including the continuous phase of a colloidal system, can still result in a stable film, especially if the product is saturated with the liquid. Temporary stability of the liquid/product system can also be achieved if the liquid dissolves very slowly within the product. If the product is an emulsion, or a suspension of liquid or solid materials in a liquid phase, then the coating liquid can be chosen, and/or modified with additives or surfactants, such that the liquid exhibits electrostatic or steric repulsive forces to the suspended phase. The additives or surfactants that stabilize the product may also diffuse to the liquid and cause it to repel the suspended phase. The use of steric or electrostatic repulsive forces to prevent agglomeration of particles or droplets in a suspension or emulsion is well understood, and any of the approaches used to achieve such suspension stability can be applied for the purpose of repelling suspended particles from interacting with the liquid or the liquid surface film. In some cases an emulsified liquid in the product may not negatively impact the properties of the liquid (and/or the liquid surface film) if mixed. For example, for embodiments in which the properties of the liquid and the product are similar, it may not be necessary to include an additive or surfactant.
Suitable products (i.e., for containing within liquid surface film coated containers of the present disclosure) include Bingham plastic materials such as toothpaste, mayonnaise, ketchup, gels, lotions, paint, and margarine. Other suitable products include foods and drugs with rheological modifiers which allow the product to exhibit Bingham plastic-like behavior. Without wishing to be bound by any theory, it is believed that in the case where the product is not a Bingham plastic, and for example, is instead a Newtonian liquid, then droplets of the liquid beneath the product would tend to float or sink along a surface, unless the product and liquid have the same density. If the liquid is partially or completely displaced by the product, and the product makes substantial contact with a surface, the product will adhere to the surface (e.g., by way of “pinning sites”), However, in the case where the product exhibits a yield stress—that is, when the product is a Bingham plastic—the buoyant force is not sufficient to overcome the yield stress, so the liquid remains trapped between the product and the surface, resulting in much less contact between the product and the surface.
In some embodiments, a container can also include a “native” coating on its interior surface(s) prior to application of the liquid. Where a container itself does not possess a suitable surface for wetting out the liquid, a suitable coating can be first applied to the interior surface(s) of the container prior to disposing the liquid within the container. For example,
The liquid can be disposed on an interior surface of the container in a number of ways. In some embodiments, the liquid is applied to the container prior to dispensing the product into the container.
In another embodiment, the liquid is applied to the product as the product is dispensed into the container. For example, as shown in
In some embodiments θop(a) is 0 degrees, where θop(a) is a receding contact angle. In some embodiments θop(a) is 0 degrees, where θop(a) is an advancing contact angle.
In some embodiments, a container may include one or more interior surfaces having a liquid disposed thereon in any manner described herein, as well as one or more interior surfaces having a liquid-impregnated surface, comprising a plurality of solid features and a liquid disposed thereon and/or therebetween, such as the liquid-impregnated surface described with reference to
While particular embodiments described herein have been illustrated and described, it would be evident to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the disclosure. All such changes and modifications are therefore also contemplated by the present disclosure, and within the scope thereof.
This application claims priority to and the benefit of U.S. Provisional Application No. 61/878,788, entitled “Articles and Methods for Forming Liquid Films on Surfaces, in Devices Incorporating the Same,” filed Sep. 17, 2013, the disclosure of which is incorporated herein by reference in its entirety.
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