The present invention relates to a container for a consumable. In particular, the present invention relates to a container for a hydratable consumable.
It is common practice for certain consumables to be supplied in a dry or hydratable form, i.e. a form in which water needs to be added to the consumable to obtain a usable product. Such consumables can include dried soup, dried pasta, dried noodles, dried rice, dried ready meals, pharmaceuticals, medicines, freeze-dried coffee, tea, hot chocolate, soft drinks, energy drinks, malted drinks, powdered desserts such as custard, blancmange, jellies and mousses, neutraceutical health products, vitamins, breakfast cereals, vending packs, third world supplies, dental health products, hair and beauty products, baby formula etc.
An advantage of supplying such consumables in a hydratable form is that it saves weight and reduces the volume of the consumable. This makes the consumable easier and cheaper to transport and also increases the shelf-life of the consumable as dried products deteriorate more slowly and are less susceptible to bacterial or fungal attack.
Containers for packaging such consumables are known. In addition, containers for packaging such consumables, which allow water to be added to the container to hydrate the consumable in situ are also known. Such containers have a relatively large volume compared to the volume of packaged consumable, i.e. the consumable occupies only a small proportion of the volume of the container. This is to allow for an increase in volume as the consumable is hydrated to create a usable product. The extra space such containers provide is only used at the point of consumption. The remainder of the time such space is of no use. The increased volume of such containers is a disadvantage because it reduces the number of containers which can be transported in a given space or stocked on a shop shelf.
The applicant sought to address the foregoing problems in their co-pending UK Patent Application No. GB 1407352.2. In general outline, this earlier application discloses a container comprising: a base; and a sidewall extending from the base; wherein the base and the sidewall define a cavity for containing a consumable; the sidewall comprising at least in part a sidewall element resiliently deformable between a compressed state in which the cavity has a first volume and an uncompressed state in which the cavity has a second volume; the sidewall element being configured to remain in the compressed state under influence of a retaining force applied to the container and automatically return to its uncompressed state when the retaining force is removed; and wherein the sidewall tapers outwards as it extends from the base. A container having a resiliently deformable sidewall element means that the sidewall element can be compressed when the container is being stored, transported or displayed in order to save space and then expanded at the point of consumption so that the consumable can be hydrated within the larger uncompressed volume of the container. Having a sidewall which tapers outwards as it extends from the base allows the container to collapse within itself as it is compressed. Additionally, it gives the container the qualities of a cup or bowl and aids consumption from the container.
The sidewall element may be compressible so that the height of the container is reduced in the compressed state compared to the uncompressed state. In particular, the sidewall element may be axially compressible.
The sidewall element may comprise a bellows-like structure, the bellows-like structure comprising alternating inwardly extending folds and outwardly extending folds connected by fold elements. A bellows-like structure is an efficient and reversible way of collapsing the sidewall of the container.
Optionally, each outwardly extending fold may be configured such that it fits within the outwardly extending fold above it and each inwardly extending fold is configured such that it fits within the inwardly extending fold above it. This further aids the container to collapse within itself as it is compressed.
An inner angle between adjacent fold elements in each pair of fold elements forming an outwardly extending fold of the bellows-like structure may be in the range of 80° to 100° when the bellows-like structure is in the uncompressed state. The angle subtended by the fold elements contributes to the way in which the bellows-like structure folds. This range of angles has been found to result in an efficient and compact folded configuration of the bellows-like structure in its compressed state and further aids the container to collapse within itself as it is compressed.
Optionally, the inner angle described above may be 87.5°. This angle has been found to be particularly conducive to producing an efficient and compact folded configuration of the bellows-like structure in its compressed state and further aids the container to collapse within itself as it is compressed.
Each outwardly extending fold may be configured to fold within the outwardly extending fold above it and each inwardly extending fold is configured to fold within the inwardly extending fold above it. This provides a space efficient folded configuration of the bellows-like structure in its compressed state and results in particularly compact container when in the compressed state.
Optionally, the bellows-like structure may be configured to fold within the cavity. This means that the bellows-like structure does not extend outside the original dimensions of the container in its uncompressed state and results in an efficient and compact folded configuration of the bellows-like structure in its compressed state.
The bellows-like structure may be configured to extend inwardly into the cavity in its compressed state in a direction transverse to the direction in which the bellows-like structure extends in its uncompressed state. This is counter to a conventional bellows which fold in a direction parallel to the direction of compression and to the direction the bellows extend in in an uncompressed state. This configuration further reduces the height of the bellows-like structure in the compressed state and further contributes to an efficient and compact folded configuration of the bellows-like structure in its compressed state.
Optionally, the fold elements may abut each other in the compressed state. This reduces wasted space between the fold elements.
The outwardly extending folds and inwardly extending folds of the bellows-like structure may be configured to assume a concentrically nested arrangement in the compressed state. This further reduces wasted space between the fold elements.
The whole of the sidewall may comprise the sidewall element. This allows the container to be compressed to a virtually flat configuration.
Optionally, a first portion of the sidewall may comprise the sidewall element and a second portion of the sidewall together with the base may define a base cavity for containing a consumable. The base cavity provides an uncompressed volume for holding a predetermined amount of consumable.
The sidewall element may be made from a resilient material. This provides a resiliently deformable sidewall element.
The container may comprise a closure for closing an opening defined by an edge of the sidewall opposite the base, wherein the closure may form an air-tight seal when attached to the container. An air-tight seal allows a vacuum to be created in the cavity of the container.
Optionally, the closure may comprise a metal foil and a thermoweldable material. A metal foil provides a strong and gas impervious closure and a thermoweldable material allows the closure to be heat sealed to the container. Consequently, the closure may be attached to the container by heat sealing.
The retaining force may comprise a vacuum formed by the closure being attached to the container when the sidewall element is in the compressed state. This maintains the container in the compressed state until the closure is opened. Furthermore, a vacuum reduces the amount of oxygen in the container which helps to preserve its contents and prolong the shelf-life of the consumable.
Optionally, an edge of the sidewall opposite the base may comprise a lip configured to provide an attachment surface for the closure. A lip increases the surface area for attachment compared to a bare edge.
An edge of the sidewall opposite the base may further comprise at least one lug. A lug can be gripped by a user in order to keep their fingers away from the sidewall of the container which may be hot.
Optionally, the lip may be smooth to facilitate drinking from the lip. Features such as screw threads can roughen the surface around the opening of a container which makes it more difficult to drink from the container.
The lip may have a wall thickness of 0.25 to 0.80 mm. This has been found to be a comfortable thickness for a user to drink from the container.
Optionally, the closure further may comprise a tab part, the tab part extending over at least a part of the lug when the closure is attached to the container, the tab part being arranged to be gripped to remove the closure from the opening. This provides a convenient way of removing the closure.
The container may be made from a heat resistant material. This allows hot drinks to be made in the container and also for the container to be microwavable.
Optionally, the container may be made from a compound comprising polypropylene or low density polyethylene. Furthermore, the compound from which the container is made may further comprise a propylene based elastomer. This allows the elastic properties of the material to be enhanced. In addition, the compound from which the container is made may further comprise ethylene vinyl alcohol copolymer (EVOH). This acts as an oxygen barrier helping to preserve the contained consumable and prolonging shelf-life.
The container may have a wall thickness of 0.275 to 0.80 mm. This range has been found to provide the container with the required rigidity to act contain a hydrated consumable but also the required elastic deformability.
Optionally, the container may comprise a secondary closure arranged to protect the closure.
The earlier application also discloses a method of containing a consumable, the method comprising: providing a container according to any of the preceding paragraphs; placing a predetermined amount of a consumable in the container; compressing the container so that the container adopts a compressed state; closing the container with a closure while the container is in the compressed state, the closure providing an air-tight seal between the container and the closure. This method allows the volume required for containing a consumable to be reduced whilst the container is being stored, transported or displayed in order to save space. The container can then be expanded by breaking the seal at the point of consumption so that the consumable can be hydrated within the larger uncompressed volume of the container.
Despite the advantages provided by the applicant's earlier container, it may be improved. Firstly, the container has to be compressed during the production process and held in the compressed state during the filling and closing steps. This requires a considerable amount of force, particularly in the case where the sidewall element is made from a resilient material. Furthermore, the container has to be held in the compressed state by a clamp, with generally the same clamp having to be used for both the filling and closing steps. This may constrain the manufacturing process and make a high volume production line more complicated and challenging to implement.
Secondly, if the retaining force is compromised, for example, the air-tight closure maintaining the vacuum is damaged, then the container will automatically start to return to the uncompressed state. Clearly this will create problems if the container is not yet ready for use, for example, if it is being transported or is being stocked on a supermarket shelf.
Aspects and embodiments of the present invention were devised with the foregoing in mind.
According to a first aspect of the present invention, there is provided a container comprising: a base; and a sidewall extending from the base; wherein the base and the sidewall define a cavity for containing a consumable; the sidewall comprising at least in part a sidewall element deformable between a compressed state in which the cavity has a first volume and an uncompressed state in which the cavity has a second volume; the sidewall element configured to be bistable such that the sidewall element will remain at rest in equilibrium in both the compressed state and the uncompressed state; wherein the sidewall element is movable between the compressed and uncompressed states by input of an activation energy to the container. Having a sidewall element that is stable in both the compressed and uncompressed states means that the sidewall will remain in the compressed state without the need to apply a retaining force to the container until a threshold activation energy is input to the container by a user and will also stably remain in the uncompressed state once returned to the uncompressed state. In other words, once compressed the container will stay compressed and once returned to the uncompressed state the container will stay in the uncompressed state. As a result there is no need to keep the container clamped in the compressed state during the filling and closing steps of the production process and there is a reduced risk of the container unintentionally returning to the uncompressed state should the closure be compromised. It will be understood that there is no requirement for the container to be fully uncompressed or for every component part of the sidewall element to be uncompressed in order for the container to be in a stable state.
The sidewall element may be compressible so that the height of the container is reduced in the compressed state compared to the uncompressed state. In particular, the sidewall element may be axially compressible.
Optionally, the bistability may be provided by the sidewall element comprising an over centre arrangement. An over centre arrangement or mechanism provides a mechanical means of implementing a bistable system.
The sidewall element may comprise a bellows-like structure, the bellows-like structure comprising alternating inwardly extending folds and outwardly extending folds connected by fold elements. A bellows-like structure is an efficient and reversible way of collapsing the sidewall of the container.
Optionally, the bellows-like structure may comprise the over-centre mechanism. This allows the over centre mechanism to directly control the bellows-like structure and hence the compressed and uncompressed states of the container.
The over-centre mechanism may comprise at least one pair of adjacent fold elements of the bellows-like structure which are non-linear. In particular, the at least one pair of adjacent fold elements of the bellows-like structure may be curved. A curve provides a continuous non-linear structure which has a natural peak for the over centre mechanism and additionally is formable by moulding.
Optionally, the curve of one of the curved fold elements of the at least one pair of adjacent fold elements may have a shorter chord length than the curve of the other one of the curved fold elements of the at least one pair of adjacent fold elements. A shorter chord length means that the compressive force compressing the container is concentrated in this shorter curve meaning that this curve goes over centre in preference to the other one of the curved fold elements of the at least one pair of adjacent fold elements.
The one of the curved fold elements of the at least one pair of adjacent fold elements having a curve of shorter chord length may be substantially W-shaped and the other of the curved fold elements of the at least one pair of adjacent fold elements may have a substantially lazy S shape. This shape naturally has two curves between its two endpoints which have shorter chord lengths compared to the chord length of a single curve formed between the two endpoints.
Optionally, adjacent pairs of fold elements forming the outwardly extending folds are spaced apart at the inwardly extending folds. This provides a gap between adjacent pairs of fold elements forming the outwardly extending folds so that the fold element that has gone over centre can be accommodated in the gap.
The sidewall may be movable between the compressed state and uncompressed state by manually applied activation energy and vice versa. This allows for manual control of the expansion and compression of the container.
A resilience of the sidewall element may be configured such that the container automatically returns to its uncompressed state from its compressed state following input of an initial activation energy to the container. This reduces the effort that has to be expended by a user.
Alternatively, a resilience of the sidewall element may be configured such that further energy has to be applied to the container to return the container to its uncompressed state from its compressed state following input of an initial activation energy to the container. This allows a user to control the return of the container to its uncompressed state and the degree of expansion.
Optionally, the sidewall comprises first and second portions which define first and second portions of the cavity respectively, wherein the first portion of the sidewall is not compressible during normal operation of the container and wherein the second portion of the sidewall comprises the sidewall element. The second portion of the sidewall provides an uncompressed volume for holding a predetermined amount of consumable.
The first portion of the sidewall may be located near an edge of the sidewall opposite the base. This provides a non-compressible part of the container near its top which can be grasped by a clamp or a user.
Optionally, the first portion and second portion may have different wall thicknesses. In particular, the wall thickness of the first portion may be thicker than the wall thickness of the second portion. By making the wall thickness of the first portion thicker this provides more rigidity to this portion of the sidewall and prevents it being compressed during normal operation. By making the wall thickness of the second portion thinner, i.e. the portion which comprises the bellows-like structure, this can be made more flexible and deformable than the remainder of the sidewall which should be more rigid.
The wall thickness of the first portion may be between 0.6 and 1.0 mm. This has been found to provide a suitably rigid first portion.
Optionally, the wall thickness of the second portion may be between 0.1 and 0.3 mm. This has been found to provide a suitably flexible and deformable second portion.
An edge of the sidewall opposite the base may define an opening, the container further comprising a closure for closing the opening. This allows the container to be filled from above, for example, by a gravity-fed hopper and then closed for storage and transport.
According to a second aspect of the present invention there is provided a method of manufacturing a container according to any one of the preceding paragraphs, the method comprising: forming a preform by injection moulding; and blow moulding at least a part of the preform to produce the container. By using a two stage manufacturing process, different properties can be imparted to different parts of the container.
The preform forming step may comprise injection moulding a first portion of a sidewall of the container, the first portion of the sidewall not being compressible during normal operation of the container. This allows a first portion of the sidewall to be given a thicker wall thickness to provide it with increased rigidity compared with the remainder of the sidewall of the container.
Optionally, the preform forming step may further comprise injection moulding the base of the container. This allows the base to also be given a thicker wall thickness.
The blow moulding step may comprise blow moulding the preform to form a second portion of the sidewall, the second portion of the sidewall comprising a sidewall element which is deformable between a compressed state and an uncompressed state. This allows the second portion of the sidewall to be given a thinner wall thickness to make it more deformable compared to the first portion of the sidewall.
In particular, the blow moulding step may comprise blow moulding a bellows-like structure. This is one way of providing a deformable structure to allow the container to be compressed and uncompressed.
Optionally, the method may comprise forming the first and second portions of the sidewall with different sidewall thicknesses. This provides for the advantageous properties discussed above.
According to a third aspect of the present invention, there is provided a method of containing a consumable, the method comprising: providing, a container according to any one of the preceding claims; compressing the container so that the container adopts a compressed state; placing a predetermined amount of a consumable in the container; closing the container with a closure. This method allows the volume required for containing a consumable to be reduced whilst the container is being stored, transported or displayed in order to save space. The container can then be expanded by breaking the seal at the point of consumption so that the consumable can be hydrated within the larger uncompressed volume of the container.
Optionally, the method of the third aspect of the present invention may be immediately preceded by the method of the second aspect of the present invention such that the method of manufacturing a container and the method of containing a consumable are carried out as part of a single continuous production process. This provides for a highly integrated and fast and efficient manufacturing process.
One or more embodiments in accordance with the present invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:
The bellows 6 is elastically deformable between an uncompressed state, as shown in
The bellows comprise a series of fold-lines 12 in the material of the cup 1 which create a series of fold elements 14. Pairs of fold elements 14 create a series of alternating outwardly extending folds 16 and inwardly extending folds 18. The outwardly extending folds 16 and inwardly extending folds 18 are annular in shape. As the bellows 6 is compressed towards the base 2, the fold elements 14 fold about the fold-lines 12 such that the angle between the fold elements 14 decreases until they abut each other. The effective height H2 constitutes the height H1 of the bellows 6 in the uncompressed state less the reduction in height of the bellows 6 as the bellows 6 are compressed into the compressed state. Viewed from the outside of the cup 1, height H2 appears to be less than the width of the angled fold elements 14. This is because at least a part of each of the fold elements 14 folds up inside the collar 5 (see
The sidewall 4 of the cup 1 tapers outwardly as it extends away from the base 2. The sidewall 4 including the bellows 6 tapers such that each successive outwardly extending fold 16 is just wider, i.e. has a larger diameter, than the outwardly extending fold 16 below it such that each outwardly extending fold 16 fits within the next outwardly extending fold 16 above it, i.e. in a direction of increasing cross-section of the cup 1. Likewise, each successive inwardly extending fold 18 has a larger diameter than the inwardly extending fold 18 below it such that each inwardly extending fold 16 fits within the next inwardly extending fold 16 above it, i.e. in a direction of increasing cross-section of the cup 1. Each outwardly extending fold 16 and each inwardly extending fold 18 is able to fold within the respective outwardly extending fold 16 and inwardly extending fold 18 above it as the bellows 6 is collapsed. The difference in diameters between the successive outwardly extending folds 16 and inwardly extending folds 18, and hence the taper of the cup 1, allows for the wall thickness of the folded material of the cup 1 and also various manufacturing tolerances.
An upper edge of the sidewall 4 of the cup 1 has a lip 22 extending transversely away from the collar 5. The lip 22 provides an attachment surface for a closure (not shown). The lip 22 is smooth and the outer edge of the lip 22 curves upwards to assist a user in drinking from the cup 1
The upper edge of the sidewall 4 also has two lugs 32 transversely extending away from the sidewall 4 and arranged in diametrically opposed positions. The lugs 32 assist with stability and comfort when holding warm drinks. For example, the cup 1 can be balanced on the lugs 32 and gripped by the lugs 32 when a hot liquid is in the cup to keep a user's fingers away from the hot sidewall 4 of the cup 1.
The base cavity 10 can contain a predetermined or metered amount of consumable. The height Hc of the base cavity 10 can be varied so that its capacity can be customised to the volume requirements of a particular consumable. The height Hc of the base cavity 10 therefore also provides an indication of when a correct amount of a consumable has been added to the cup 1. The cup 1 would typically contain drinkable consumables such as dried tea, coffee, etc., although other consumables can be contained.
As discussed above, the bellows 6 comprise a series of fold elements 14.
The bellows 6 are elastic and resiliently act to urge the bellows 6 back to their uncompressed state. This reduces the pressure inside the cup 1. This creates a pressure differential between the outside of the cup 1 and the inside of the cup 1 with the pressure inside the cup 1 being lower than the ambient pressure outside the cup 1, i.e. a vacuum is created inside the cup 1. Air cannot enter the cup 1 due to the air-tight seal between the lip 22 and closure 30. Consequently, the ambient air pressure acting over the area of the closure 30 creates a retaining force which maintains the cup 1 in the compressed state.
To provide the required resilience, the bellows are made from an elastic polymeric material. For ease of manufacture, the bellows 6 are generally made from the same material as the remainder of the cup 1, although different materials can be used. The cup 1 is made from a compound comprising 75-90% polypropylene or low density polyethylene (LDPE). To increase the resilient qualities of the bellows 6 a propylene based elastomer such as Vistamaxx™ manufactured by ExxonMobil Chemical can be added to the compound. The propylene based elastomer has added benefits in that it allows the wall thickness of the cup 1 to be reduced and increases the strength of the cup 1. The wall thickness of the cup 1 can be between 0.275-0.8 mm. The wall thickness of the lip 22 can be 0.250-0.8 mm. In addition, to make the cup 1 more impervious to oxygen, 3-6% of ethylene vinyl alcohol copolymer (EVOH) can be added to the compound to provide an oxygen barrier in order to extend shelf-life and preserve the consumable.
The closure is a laminate structure comprising a metal foil layer and a heat seal layer. The metal foil is made from aluminium and is approximately 70 micron in thickness. The heat seal layer is based on polypropylene and is approximately 25 micron in thickness. In addition, the closure can comprise an over-lacquer and be printed.
The structural features of cup 101, bowl 200 and bowl 300 are the same as cup 1 in
The cup 101, bowl 200 and bowl 300 can be provided with the same closure as provided for cup 1 (see
The containers, i.e. cup 1, cup 101, bowl 200 and bowl 300, can be used: i) for containing a consumable for storage, transportation and display; and ii) as a container for hydrating a consumable at the point of consumption. Both these uses will be described below with respect to cup 1 of
To contain a consumable for storage, transportation and display, cup 1 is filled with a consumable. The cup 1 is held and compressed to its compressed state with a compressive force. A closure 30 is then sealed to lip 22 in order to provide an air-tight seal between the lip 22 and the closure 30. The compressive force can then be removed. As discussed above, due to the lower air pressure (partial vacuum) created inside the cup 1 by the bellows 6 trying to expand, the cup 1 is maintained in the compressed state, i.e. lower air pressure provides a retaining force which keeps the cup 1 compressed. The cup 1 is now ready to be stored, transport or displayed as required.
To use the cup 1 at the point of consumption, a user peels back closure 30 from at least a part of the lip 22 so that air can enter the inner volume of the cup 1. The cup 1 expands unassisted under the resilient action of the bellows 6 to its uncompressed state. The volume of the cup 1 in its uncompressed state is significantly greater than in its compressed. Water can be added to hydrate the consumable such that the uncompressed volume of the cup 1 can be used to produce the hydrated consumable.
The bellows-like structure 406 is deformable between an uncompressed state, as shown in
The bellows-like structure 406 is stable in both the uncompressed state and the compressed state, i.e. the bellows-like structure 406 has bistability. This means that when the cup 401 is compressed it remains at rest in the compressed state without the need for any retaining force and when the cup 401 is in the uncompressed state it will remain in the uncompressed state without the need for a retaining force. This is achieved by means of an over centre mechanism comprised in the bellows-like structure 406 which is discussed in more detail below. The cup is able to return from the compressed state to the uncompressed and vice versa by input of an activation energy to the cup by a user, i.e. an input energy above a certain threshold value.
The bellows-like structure 406 comprises a series of fold-lines 412 in the material of the cup 401 which create a series of fold elements 414a and 414b. Pairs of fold elements 414a and 414b create a series of alternating outwardly extending folds 416 and inwardly extending folds 418. Each outwardly extending fold comprises an upper fold element 414a and a lower fold element 414b. The outwardly extending folds 416 and inwardly extending folds 418 are annular in shape.
As the bellows-like structure 406 is compressed towards the base 402, the fold elements 414a and 414b fold about the fold-lines 412 such that the angle between the fold elements 414a and 414b decreases and the height of the bellows-like structure 406 decreases. A portion of the bellows-like structure 406 may fold up inside the collar 5 (see
The sidewall 404 of the cup 401 tapers gently outwards as it extends away from the base 402. The sidewall 404 including the bellows-like structure 406 tapers such that each successive outwardly extending fold 416 is just wider, i.e. has a larger diameter, than the outwardly extending fold 416 below it such that each pair of fold elements 414a and 414b forming an outwardly extending fold 416 fits within the next pair of fold elements 414a and 414b forming an outwardly extending fold 416 above it, i.e. in a direction of increasing cross-section of the cup 401. Likewise, each successive inwardly extending fold 418 has a larger diameter than the inwardly extending fold 418 below it. As a result, successive pairs of fold elements 414a and 414b forming outwardly extending folds 416 are able to nest within the pair of fold elements 414a and 414b above it as the bellows-like structure 406 is collapsed (see
An upper edge of the sidewall 404 of the cup 401 has a lip 422 extending transversely away from the collar 405. The lip 422 is smooth and the outer edge of the lip 422 curves upwards to assist a user in drinking from the cup 401. The cup 401 is circular in cross-section similar to the cup 1 shown in
As discussed above, the bellows-like structure 406 comprises a series of fold elements 414a and 414b. Referring again to
Outwardly extending folds 416 are formed as small U-shaped ridges. These ridges extend outwardly from the cup 401 and around the entirety of the circumference of the cup, i.e. they are annular ridges. Due to their ridged shape, the outwardly extending folds 416 provide rigidity and stiffness to the cup 401, particularly in the plane of the annulus. The inwardly extending folds 418 are also formed as small ridges. Fold elements 414a and 414b which form each inwardly extending fold 418 are slightly spaced apart and joined by a small section of sidewall 404 to form a spacer 414c (see
The curved fold elements 414a and 414b together with the outwardly 416 and inwardly 418 extending folds form an over centre mechanism which provides bistability to the bellows-like structure 406. In an over centre mechanism energy is imparted to the system in a first stable position to move it just past a peak at which point the mechanism goes “over centre” and moves to it to a second stable position. This creates a toggle-type action such that energy input to the system which is less than a certain threshold required to move the system from a stable position to the peak has no effect on the system, i.e. it remains in its current state, whereas energy input to the system which is more than a certain threshold moves the system from its current stable state to its other stable state.
A downwards force F is applied to the upper side of curved element 508. As shown in
The amount of energy required to move the curved element 508 from its first stable position in which the midpoint of the element is at point X1 to the point that it snaps past the line joining points A and B is called the activation energy. A similar amount of energy is required to move the curved element 508 from its second stable position in which the midpoint of the element is at point X2 back past the line joining points A and B.
This is more clearly illustrated in
Of course, it will be appreciated that
By the time the cup 401 reaches its fully compressed state all of curves 414b(ii) of all the fold elements 414b of the bellows-like structure will have moved over centre to arc in the opposite direction and the bellows-like structure will adopt the configuration shown in
If an opposite expansive force away from the base is applied to the cup 401 in a direction parallel to the longitudinal axis of the cup 401, the above process will happen in reverse and the cup 401 will return to its uncompressed configuration in
The activation energy required to move the curves 414b(ii) over centre is designed to be easily achievable by an average user and is typically that which can be applied by hand. For example, a user can grasp the collar 405 and base 402 between thumb and fingers of each hand and the cup 401 can be compressed or expanded with minimal strength due to the design which concentrates the force applied in curve 414b(ii). A user can tell as each curve moves over centre because they will hear a clicking sound.
In one embodiment, the cup 401 is produced by means of injection stretch blow moulding. This is a two-part process. Firstly, a plastics preform having the collar 405, lip 422 and base 402 features is fabricated by injection moulding. Secondly, the preform is placed into a further mould where it is heated to make the plastics more pliable and compressed air is blown into the mould in order to blow mould the bellows-like structure 406. This two-part process allows the wall thickness of different parts of the cup 401 to be controlled. The injection moulding step can be used to give the collar, lip and base a thicker wall thickness, whereas, the blow moulding step stretches the plastic to conform to the mould resulting in a reduced wall thickness and rigidity of the bellows-like structure 406. The wall thickness of the collar 405 of the cup 401 can be between 0.6 and 1.0 mm. The same thicknesses can also be applied to the base 402 and lip 422. The wall thickness of the bellows-like structure 406 of the cup 401 can be between 0.1 and 0.3 mm. In one embodiment, the wall thickness of the collar 405 of the cup 401 is 0.8 mm and the wall thickness of the bellows-like structure 406 is 0.2 mm. Of course, it will be appreciated that thicker or thinner wall thickness can be used. The wall thickness also affects the resilience of the bellows-like structure, with a thicker wall thickness generally resulting in a more resilient structure. The wall thickness ultimately depends on the thickness given to different parts of the preform when the preform is fabricated and this can be controlled during the injection moulding process. The same manufacturing process and properties can also be applied to the cup 501.
The cups 401 and 501 are generally made from a plastics material and can be used to contain both hot and cold products. For hot products, polypropylene is the preferred material. For cold or room temperature products, polyethylene terephthalate or PET is the preferred material. However, it will be appreciated that other materials can be used. Furthermore, additives may be added to the cup material to adjust its properties such as resilience or colour, etc.
A container according to the invention, i.e. cups 401 and 501, can be used: i) for containing a consumable for storage, transportation and display; and ii) as a container for hydrating a consumable at the point of consumption. Both these uses will be described below with respect to cup 401. However, the skilled person will appreciate that cup 501 or any other container according to the invention can be used in the same way.
To contain a consumable for storage, transportation and display, cup 401 is firstly compressed to its compressed state. As the cup 401 stably remains in the compressed state of its own accord there is no need to apply a retaining force. The cup 401 is then filled with a consumable. Alternatively, the cup 401 could be filled with a consumable before it is compressed. Once the container has been compressed and filled a closure is applied to the opening in order to seal the consumable within the cup 401. The cup 1 is now ready to be stored, transported or displayed as required.
To use the cup 401 at the point of consumption, a user removes the closure in order to gain access to the consumable and prevent a vacuum forming when they try to expand the cup 401. The user gently pulls the collar 405 or lip 422 away from the base to cause at least a few of the curves 414b(ii) of the bellows-like structure 406 to move over centre. Depending on the degree of resilience that has been incorporated in the material, the cup 401 with then either return to the uncompressed state of its own accord due to the potential energy stored in the bellows-like structure or a user can pull the cup 401 to its fully uncompressed state. The volume of the cup 401 in its uncompressed state is significantly greater than in its compressed volume. Water can then be added to hydrate the consumable such that the uncompressed volume of the cup 401 can be used to produce the hydrated consumable.
As used herein any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” or the phrase “in an embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
In addition, use of the “a” or “an” are employed to describe elements and components of the invention. This is done merely for convenience and to give a general sense of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.
In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention. A container may be provided which does not have a base cavity and which is not intended to contain a consumable so that the container can be compressed to an even greater extent, i.e. to a virtually flat shape. Such a container would provide a means of saving space where space is at a premium and may find application in hotel and hostels, on ships, for camping or in the military.
The container may have a secondary lid in order to protect the closure. The container may be made from a heat resistant material, i.e. a material which is able to withstand temperatures of up to 100° C. (the boiling point of water at sea level) without loss of structural strength or integrity to allow for the preparation of hot drinks and foodstuffs. Furthermore, the container may be configured so that it is microwave and freezer safe. The container may be made from a material which is able to withstand temperatures in excess of 100° C. to allow food and drinks to be cooked in the container in a microwave. In addition, the container may be configured so that it is recyclable.
Various different materials may be suitable for the container. For example, the container can be made out of waxed or coated cardboard or other coated fibrous materials, although polymers are generally preferred due to their advantageous properties. For example, the container including the bellows may be made from one or more materials selected from the following list: Thermoplastic Urethane; Polypropylene; Random & Block Copolymer; Homo Polymer; Low Density Polyethylene (LDPE); High Density Polyethylene (HDPE); Linear Low Density Polyethylene (LLDPE); Thermoplastic Elastomers (TPE); Thermoplastic Ethylene (TPE); Thermoplastic Olefins (TPO). Furthermore, various different additives for providing the elastic and oxygen barrier properties of the container may be used. The elasticity of the container is dependent on the particular mix of materials used. The elasticity has been found to be generally related to the density of the material mix used. A density of 0.923 g/cm3 has been found to be particularly suitable. In addition, tie layers may be used. These are melt layers which help other laminates or additives such as EVOH to bond to the other polymers.
Various different materials may also be suitable for the closure. For example, the closure does not need to comprise a metal foil. A closure comprising only a polymeric film such as polypropylene or LDPE may also be used.
Although the specific description refers to the fold elements 14 being aligned in parallel when the bellows 6 are compressed, the term “parallel” is not used in a strict geometric sense and compliance with a strict geometric meaning is not intended or necessary for an embodiment of the invention.
Embodiments have been described using air as the gas in the container when compressed. However, the ordinarily skilled person would recognise that an inert gas, such as nitrogen, may be introduced into the container to create a substantially nitrogen atmosphere in the container albeit at a lower pressure than ambient atmospheric pressure.
Although a specific embodiment in accordance with the invention has been described utilising ridges, particularly U-shaped ridges, forming the outwardly and inwardly extending folds, embodiments in accordance with the invention may use different shaped ridges, ridges on just one or other of the outwardly and inwardly extending folds, or no ridges at all.
The scope of the present disclosure includes any novel feature or combination of features disclosed therein either explicitly or implicitly or any generalisation thereof irrespective of whether or not it relates to the claimed invention or mitigate against any or all of the problems addressed by the present invention. The applicant hereby gives notice that new claims may be formulated to such features during prosecution of this application or of any such further application derived therefrom. In particular, with reference to the appended claims, features from dependent claims may be combined with those of the independent claims and features from respective independent claims may be combined in any appropriate manner and not merely in specific combinations enumerated in the claims.
In addition, the order of the various elements of the independent method claim does not imply that the elements have to be carried out in any particular order. For the avoidance of doubt, the container can either be compressed and then the consumable placed in the container or the consumable can be placed in the container and then the container compressed.
Number | Date | Country | Kind |
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1407352.2 | Apr 2014 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2015/058995 | 4/24/2015 | WO | 00 |