PROCESS FOR GAMMA-BUTYROLACTONE PRODUCTION

Abstract

A double-walled plastic jar for cosmetic materials, having an inner compartment to hold the cosmetic, and an annular outer side wall defining the exterior of the jar. The inner compartment carries the lip that seals with a screw cap, and also carries an external skirt, which latter has the screw threads for engagement by the cap. In addition, a weight is disposed in a-concealed manner in the base of the jar, between the walls, to give the jar a heft feel, characteristic of glass or thick plastic walls.

Description

TECHNICAL FIELD

The invention relates to a container assembly of thin/economically produced parts which simulate an image and weight of an expensive cosmetic jar.

BACKGROUND ART

There have been many styles of plastic double walled containers devised over the years. For high-end cosmetic products, normally a single piece glass or plastic jar with a very thick wall cross section has been preferred. The objective was to offer a feeling of quality and heft. However, molding these thick walled jars in plastic is expensive, due to both the high volume of expensive resin, and the long molding machine cycle time.

A double walled container is typically made of two assembled parts; an inner cup, which serves as a vessel for the product when sealed with a cap, and an outer cosmetic jar part, which is shaped to look like a cosmetic jar body. A threaded closure or cap would normally engage a threaded portion of the jar, allowing the contents to remain sealed until opened by the consumer.

The use of clear plastic to create the outer wall of a typical double walled container usually allows any mechanical fitment means/features between the inner and outer parts to be visible by the consumer, which removes the image of quality and prestige the customer wants to convey in their packaging. With the use of a threaded closure and threaded neck form on a jar, any assembly of individual components to create this must be able to withstand the normal torque and axial forces associated with these types of features during filling and use. The use of clear Styrenic and Acrylic resins for the threaded portion of the jar for products containing volatiles or fragrance oils can lead to chemical compatibility issues and subsequent package failures, like stress cracking under load.

DISCLOSURE OF INVENTION

This invention offers a new and unobvious solution to the problem of clear cosmetic jar parts and the accompanying visibility of unsightly mechanical securements needed to assemble them. With the invention, such mechanical securements are desirably positioned completely inside of the jar neck area. In cases where the use of an opaque resin for the threaded jar liner, there is obscured the consumer's view of the mechanical securements needed to fasten the parts together.

Due to the placement of these securements within the neck area, the typical shoulder area of a common cosmetic jar can then be formed in the outer clear part. Visually, this is much more appealing than seeing mechanical securements within the shoulder area. The clear, unbroken shoulder area conveys a desired look and feel of a high end glass jar.

The invention provides a plastic jar for cosmetic materials, said jar being adapted to receive a screw cap, and said jar comprising, in combination a substantially annular inner side wall and a transverse bottom wall formed integrally therewith, said walls defining a compartment to hold the cosmetic material, a substantially annular outer side wall defining an exterior of the jar, said annular inner side wall having an upper lip for sealing engagement with the screw cap, an exterior skirt integrally formed with said lip, said skirt being spaced from said annular inner side wall and provided with screw threads on its exterior surface, for engagement by the screw threads of said screw cap, said outer annular side wall having an upper lip, said upper lip of the annular inner side wall and skirt forming a downwardly facing groove to receive the upper lip of the annular outer side wall, said latter upper lip extending into said groove to an extent whereby it directly underlies the screw threads of the skirt, and anti-rotation means on a wall of the groove and on the upper lip of the annular outer side wall, operative to prevent inadvertent rotation or shifting between the annular inner side wall and the annular outer side wall.

Other features and advantages will hereinafter appear.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a vertical section of the double-walled jar of the invention as assembled. The jar comprises an annular inner side wall and an annular outer side wall, as well as a bottom plug connected to both walls.

FIG. 2 is an exploded view of the components of the jar of FIG. 1.

FIG. 3 is a view like FIG. 1, except prior to assembly of the bottom plug of the jar to the annular walls thereof.

FIGS. 4, 5 and 6 are detail views, respectively, of the construction of portions of the jar of FIG. 1.

FIG. 7 is a perspective view of the jar of FIG. 1, except with a broken-away area, showing the cooperation of the threads of the jar with the underlying outer annular wall.

FIG. 8 is an exploded view of the jar of FIG. 1, and further including a screw cap therefor, constituting a jar lid.

FIG. 9 a perspective view of the annular outer side wall per se.

FIG. 10 is a view like FIG. 1, of a modified double-walled jar and wherein the bottom wall is integrally molded with annular side wall of the jar.

FIG. 11 is a front elevation of a further modified jar having a polygonal outer annular wall as opposed to the cylindrical configuration shown in the previous figures, and

FIG. 12 is a section on the line 12-12 of FIG. 11.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention comprises essentially several separate thin-walled plastic components which are fitted together to form a double-walled jar. The jar is intended to hold a quantity of cosmetic product (not shown), and at the same time, impart to the consumer, a heft or solid feel to the jar, simulating that of thick walled plastic, or else high quality molded glass.

Referring now to FIGS. 1-6, there is shown in section, and fragmentary section, the inner member or compartment of the jar, comprising an annular inner side wall generally designated by the numeral 10, having a transverse bottom wall 12, and an annular outer side wall 14. Connected to the annular outer side wall 14 is a bottom plug 16 held in place by a retainer structure to be described below. The annular outer side wall 14 and bottom plug 16 thus define the exterior of the jar.

In accordance with the invention, the annular inner side wall 10 extends upwardly to a lip 18, which is intended to seal against a liner 20 of a screw cap 22, the latter being shown in the view labeled FIG. 8. Connected integrally with the lip 18 is a downwardly extending annular skirt 24, the skirt 24 and outer surface of the lip 18 forming a downwardly facing groove 26, FIG. 2. Screw threads 23 are also provided on the skirt's outer surface, as shown. By the invention cooperable anti-rotation structures comprising shoulders 28 (FIG. 7) on the side wall of the groove 26 and cooperable shoulders 30 on the annular outer side wall 14, are arranged to engage one another, being operative to prevent relative turning movement between the compartment defined by the walls 10 and 12, and the annular outer side wall 14. In practice the shoulders 28 and 30 are constituted as vertical ribs. The upper part of the annular inner side wall 10 has an external shoulder 32 which is engaged by the bottom edge of the skirt 24 as the latter becomes fully seated thereon. Optionally, cooperable retainer means in the form of a bead and groove formation 33, FIG. 4, on the skirt 24 and on the annular outer side wall 14 at the external shoulder 32 thereof, are provided for increased strength and stability.

In accomplishing the securement of the plug 16, the latter is provided with an upstanding skirt 34, FIG. 6, which is arranged to mate with a similarly-sized downwardly extending skirt 36 at the junction of the annular inner side wall 10 and transverse bottom wall 12. On the outer surface of the skirt 34 is a further retention arrangement involving cooperable bead/groove formations 38, which function to retain the bottom plug 16 in position. Preferably the plug 16 is snapped into the opening at the bottom of the annular outer side wall 12. The plug 16 can have a recess 42 to receive a label or appliqué (not shown), that can contain advertising material or instructions relating to the product contained in the jar.

Further by the invention, the upstanding skirt 34 of the plug 16 has, on its inner surface 44, a resilient or crushable formation 46 (FIG. 2) of plastic material, and a weight 48 which operates to give the jar a heavier feel, similar to that of thick plastic or glass. The weight 48 is in the form of a disk, and is held in place by being pressed into the well formed by the skirt 34, and crushing the plastic as it is forced into place. The resilience of the crushed plastic retains the weight in position in the plug 16, and prevents it from inadvertently shifting or rattling in the completed jar.

With the present invention there is realized an improved stability in the area of the screw threads. Preferably, the plastic utilized is polypropylene. Polypropylene has the advantage of low cost and chemical compatability requirements with the enclosed cosmetic product. The use of polypropylene for the lip and skirt areas circumvents any tendency toward stress cracking under load, and its use is a major advantage over the use of styrenics or acrylics in place of the polypropylene.

Further, by virtue of the provision of the interengaging shoulders 28 and 30, FIGS. 7 and 9, which are disposed radially underneath the screw threads 23, forces encountered during screwing or unscrewing of a screw cap 22 are countered by the immediately-adjacent shoulders 28, 30, and the resulting construction also provides the high resistance to stress cracking noted above, especially with certain cosmetic solvents, and after the plastic adjacent the screw threads has aged an extent.

Another embodiment of the invention is illustrated in FIG. 10, showing a slightly modified double walled jar 60. The construction involving retention of the inner and outer side walls 62 and 64 respectively, is essentially as described above. The increased strength of the skirt 66 is also retained in the present construction.

By the invention, a weight 68 is fitted into the downwardly extending skirt 70 on the bottom wall 72 and held therein by a bead 74, or by suitable cement.

In this embodiment the exterior of the jar is defined by the annular outer side wall 64 and an integral bottom wall 78. The appearance from the exterior would be the same as that of a normal heavy walled jar. The weight would be hidden from view by the skirt 70, or by a label applied to a very shallow recessed portion 82 in the underside surface 80 of the jar exterior. The provision of the weight 68 gives this jar the same hefty feel as a high-end container product. By using a blow molded exterior, typical uniform wall thickness jar shapes can be created, moreover of a type not heretofore achievable for use in a straight pull design.

One additional embodiment is illustrated in FIGS. 11 and 12, wherein the structural details are generally the same as those of the embodiment of FIG. 1, except that the outer wall is not cylindrical, but instead polygonal. The area above the neck is round, to accommodate the usual screw cap, as before. In other respects this version is similar to FIG. 1. It is understood that with the present arrangement, almost any geometrical configuration can be used for the outer wall.

From the above it can be seen that we have provided a novel and improved jar construction which is both simple in its structure and economical to manufacture. The look and feel of high-end jars is retained utilizing essentially solely thin plastic components. The parts are assembled to produce in a unique manner, concealment from view from outside the jar, of structural parts involved with their retention of the jar in its assembled position. Finally, the overall integrity of the construction and the elimination of possible failure from cracking of the plastic, or degradation from contact with cosmetic chemicals is achieved.

The disclosed containers are thus seen to represent a distinct advance and improvement in the field of closures and cosmetic storage and dispensing.

Each and every one of the appended claims defines an aspect of the invention which is separate and distinct from all others, and accordingly it is intended that each claim be treated as such when examined in the light of the prior art devices in any determination of novelty or validity.

Variations and modifications are possible without departing from the spirit of the claims.

LISTING OF REFERENCE NUMERALS

• 10 Annular inner side wall
• 12 Transverse bottom wall
• 14 Annular outer side wall
• 16 Bottom plug
• 18 Lip
• 20 Liner
• 22 Screw cap
• 23 Screw threads
• 24 Annular skirt
• 26 Groove
• 28 Shoulders or vertical ribs on wall 10
• 30 Cooperable shoulders or vertical ribs on skirt 24
• 32 External shoulder
• 33 Bead/groove
• 34 Plug's upstanding skirt
• 36 Downwardly extending skirt
• 38 Bead/groove
• 42 Recess in plug
• 44 Inner surface of upstanding skirt
• 46 Crushable or resilient plastic projection
• 48 Weight
• 50 Groove/bead
• 52 Groove/bead
• 54 Interengaging groove/bead formation
• 56 Interengaging groove/bead formation
• 60 Modified jar
• 62 Annular inner side wall
• 64 Annular outer side wall
• 66 Skirt
• 68 Weight
• 70 Depending skirt
• 72 Bottom wall
• 74 Bead
• 76 Annular outer side wall
• 78 Integral bottom wall
• 80 Underside surface

Claims

1. A process for production of a biobased gamma-butyrolactone product, comprising a) combining a genetically engineered biomass comprising poly-4-hydroxybutyrate and a catalyst; andb) heating the biomass with the catalyst to convert the poly 4-hydroxybutyrate to a gamma-butyrolactone product.

2. The process of claim 1, wherein the genetically engineered biomass is from a recombinant host having a poly-4-hydroxybutyrate pathway, wherein the host has an inhibiting mutation in its CoA-independent NAD-dependent succinic semialdehyde dehydrogenase gene or its CoA-independent NADP-dependent succinic semialdehyde dehydrogenase gene, or having the inhibiting mutations in both genes, and having stably incorporated one or more genes encoding one or more enzymes selected from a succinyl-CoA:coenzyme A transferase wherein the succinyl-CoA:coenzyme A transferase is able to convert succinate to succinyl-CoA, a succinate semialdehyde dehydrogenase wherein the succinate semialdehyde dehydrogenase is able to convert succinyl-CoA to succinic semialdehyde, a succinic semialdehyde reductase wherein the succinic semialdehyde reductase is able to convert succinic semialdehyde to 4-hydroxybutyrate, a CoA transferase wherein the CoA transferase is able to convert 4-hydroxybutyrate to 4-hydroxybutyryl-CoA, and a polyhydroxyalkanoate synthase wherein the polyhydroxyalkanoate synthase is able to polymerize 4-hydroxybutyryl-CoA to poly-4-hydroxybutyrate.

3. The process of claim 1, wherein the genetically engineered biomass is from a recombinant host having stably incorporated one or more genes encoding one or more enzymes selected from: a phosphoenolpyruvate carboxylase wherein the phosphoenolpyruvate carboxylase is able to convert phosphoenolpyruvate to oxaloacetate, an isocitrate lyase wherein the isocitrate lyase is able to convert isocitrate to glyoxalate, a malate synthase wherein the malate synthase is able to convert glyoxalate to malate and succinate, a succinate-CoA ligase (ADP-forming) wherein the succinate-CoA ligase (ADP-forming) is able to convert succinate to succinyl-CoA, an NADP-dependent glyceraldeyde-3-phosphate dehydrogenase wherein the NADP-dependent glyceraldeyde-3-phosphate dehydrogenase is able to convert glyceraldehyde 3-phosphate to 1,3-bisphosphoglycerate forming NADPH+H+, an NAD-dependent glyceraldeyde-3-phosphate dehydrogenase wherein the NAD-dependent glyceraldeyde-3-phosphate dehydrogenase is able to convert glyceraldehyde 3-phosphate to 1,3-bisphosphoglycerate forming NADH+H+, a butyrate kinase wherein the butyrate kinase is able to convert 4-hydroxybutyrate to 4-hydroxybutyryl-phosphate, a phosphotransbutyrylase wherein the phosphotransbutyrylase is able to convert 4-hydroxybutyryl-phosphate to 4-hydroxybutyryl-CoA; and optionally having a disruption in one or more genes selected from yneI, gabD, pykF, pykA, maeA and maeB.

4. The process of claim 1, wherein the process further includes an initial step of culturing a recombinant host with a renewable feedstock to produce a poly-4-hydroxybutyrate biomass.

5. The process of claim 4, wherein a source of the renewable feedstock is selected from glucose, fructose, sucrose, arabinose, maltose, lactose, xylose, fatty acids, vegetable oils, and biomass derived synthesis gas or a combination thereof.

6. The process of claim 1, wherein the biomass host is a bacteria, yeast, fungi, algae, cyanobacteria, or a mixture of any two or more thereof.

7. The process of claim 6, wherein the biomass host is bacteria.

8. The process of claim 7, wherein the bacteria is selected from Escherichia coli, Alcaligenes eutrophus (renamed as Ralstonia eutropha), Bacillus spp., Alcaligenes latus, Azotobacter, Aeromonas, Comamonas, Pseudomonads), Pseudomonas, Ralstonia, Klebsiella), Synechococcus sp PCC7002, Synechococcus sp. PCC 7942, Synechocystis sp. PCC 6803, Thermosynechococcus elongatus BP-I, Chlorobium tepidum, Chloroflexusauranticus, Chromatium tepidum and Chromatium vinosum Rhodospirillum rubrum, Rhodobacter capsulatus, and Rhodopseudomonas palustris.

9. The process of claim 6, wherein the recombinant host is algae.

10. The process of claim 1, wherein heating is at a temperature of from about 100° C. to about 350° C.

11. The process of claim 1, wherein the catalyst is sodium carbonate or calcium hydroxide.

12. The process of claim 11, wherein the weight percent of catalyst is in the range of about 4% to about 50%.

13. The process of claim 1 any one of claims 1-12, wherein heating reduces the water content of the biomass to about 5 wt %, or less.

14. The process of claim 1, wherein the heating temperature is from about 200° C. to about 350° C.

15. The process of claim 14, wherein the heating temperature is from about 225° C. to about 300° C.

16. The process of claim 1, wherein the heating is for a time period from about 30 seconds to about 5 minutes.

17. The process of claim 1, wherein the heating is for a time period from about 5 minutes to about 2 hours.

18. The process of claim 1, further comprising recovering the gamma-butyrolactone product.

19. The process of claim 1, wherein the gamma-butyrolactone product comprises less than 5% by weight of side products.

20. The process of claim 1, wherein the gamma-butyrolactone is further processed to form one or more of the following: 1,4-butanediol (BDO), tetrahydrofuran (THF), N-methylpyrrolidone (NMP), N-ethylpyrrolidone (NEP), 2-pyrrolidinone, N-vinylpyrrolidone (NVP) and polyvinylpyrrolidone (PVP).

21. The process of claim 1, wherein the genetically engineered biomass is from a recombinant host having a poly-4-hydroxybutyrate pathway, wherein the host has optionally an inhibiting mutation in its CoA-independent NAD-dependent succinic semialdehyde dehydrogenase gene or its CoA-independent NADP-dependent succinic semialdehyde dehydrogenase gene, or having inhibiting mutations in both genes, and having stably incorporated genes encoding the following enzymes: a succinyl-CoA:coenzyme A transferase wherein the succinyl-CoA:coenzyme A transferase is able to convert succinate to succinyl-CoA, a succinate semialdehyde dehydrogenase wherein the succinate semialdehyde dehydrogenase is able to convert succinyl-CoA to succinic semialdehyde, a succinic semialdehyde reductase wherein the succinic semialdehyde reductase is able to convert succinic semialdehyde to 4-hydroxybutyrate, a CoA transferase wherein the CoA transferase is able to convert 4-hydroxybutyrate to 4-hydroxybutyryl-CoA, and a polyhydroxyalkanoate synthase wherein the polyhydroxyalkanoate synthase is able to polymerize 4-hydroxybutyryl-CoA to poly-4-hydroxybutyrate.

22. The process of claim 1, wherein the genetically engineered biomass is from a recombinant host having stably incorporated genes encoding the following enzymes: a phosphoenolpyruvate carboxylase wherein the phosphoenolpyruvate carboxylase is able to convert phosphoenolpyruvate to oxaloacetate, an isocitrate lyase wherein the isocitrate lyase is able to convert isocitrate to glyoxalate, a malate synthase wherein the malate synthase is able to convert glyoxalate to malate and succinate, a succinate-CoA ligase (ADP-forming) wherein the succinate-CoA ligase (ADP-forming) is able to convert succinate to succinyl-CoA, an NADP-dependent glyceraldeyde-3-phosphate dehydrogenase wherein the NADP-dependent glyceraldeyde-3-phosphate dehydrogenase is able to convert glyceraldehyde 3-phosphate to 1,3-bisphosphoglycerate forming NADPH+H+, an NAD-dependent glyceraldeyde-3-phosphate dehydrogenase wherein the NAD-dependent glyceraldeyde-3-phosphate dehydrogenase is able to convert glyceraldehyde 3-phosphate to 1,3-bisphosphoglycerate forming NADH+H+, a butyrate kinase wherein the butyrate kinase is able to convert 4-hydroxybutyrate to 4-hydroxybutyryl-phosphate, a phosphotransbutyrylase wherein the phosphotransbutyrylase is able to convert 4-hydroxybutyryl-phosphate to 4-hydroxybutyryl-CoA; and optionally having a disruption in one or more genes selected from yneI, gabD, pykF, pykA, maeA and maeB.

23. The process of claim 1, wherein the genetically engineered biomass is from a recombinant host having a poly-4-hydroxybutyrate pathway, wherein the host has stably incorporated one or more genes encoding one or more enzymes selected from a succinyl-CoA:coenzyme A transferase wherein the succinyl-CoA:coenzyme A transferase is able to convert succinate to succinyl-CoA, a succinate semialdehyde dehydrogenase wherein the succinate semialdehyde dehydrogenase is able to convert succinyl-CoA to succinic semialdehyde, a succinic semialdehyde reductase wherein the succinic semialdehyde reductase is able to convert succinic semialdehyde to 4-hydroxybutyrate, a CoA transferase wherein the CoA transferase is able to convert 4-hydroxybutyrate to 4-hydroxybutyryl-CoA, and a polyhydroxyalkanoate synthase wherein the polyhydroxyalkanoate synthase is able to polymerize 4-hydroxybutyryl-CoA to poly-4-hydroxybutyrate.

24. The process of claim 1, wherein the genetically engineered biomass is from a recombinant host having stably incorporated one or more genes encoding one or more enzymes selected from: a phosphoenolpyruvate carboxylase wherein the phosphoenolpyruvate carboxylase is able to convert phosphoenolpyruvate to oxaloacetate, an isocitrate lyase wherein the isocitrate lyase is able to convert isocitrate to glyoxalate, a malate synthase wherein the malate synthase is able to convert glyoxalate to malate and succinate, a succinate-CoA ligase (ADP-forming) wherein the succinate-CoA ligase (ADP-forming) is able to convert succinate to succinyl-CoA, an NADP-dependent glyceraldeyde-3-phosphate dehydrogenase wherein the NADP-dependent glyceraldeyde-3-phosphate dehydrogenase is able to convert glyceraldehyde 3-phosphate to 1,3-bisphosphoglycerate forming NADPH+H+, an NAD-dependent glyceraldeyde-3-phosphate dehydrogenase wherein the NAD-dependent glyceraldeyde-3-phosphate dehydrogenase is able to convert glyceraldehyde 3-phosphate to 1,3-bisphosphoglycerate forming NADH+H+, a butyrate kinase wherein the butyrate kinase is able to convert 4-hydroxybutyrate to 4-hydroxybutyryl-phosphate, a phosphotransbutyrylase wherein the phosphotransbutyrylase is able to convert 4-hydroxybutyryl-phosphate to 4-hydroxybutyryl-CoA; and optionally having a disruption in one or more genes selected from yneI, gabD, pykF, pykA, maeA and maeB.

25. The process of claim 1, wherein the weight % of the catalyst is in the range of about 4% to about 50%, and the heating is at about 300° C.

26. The process of claim 1, wherein the catalyst is about 4% by weight calcium hydroxide and the heating is at a temperature of 300° C.

27. A biobased gamma-butyrolactone product produced by the process of claim 1.

28. The product of claim 27, wherein the gamma-butyrolactone product comprises less than 5% by weight of side products.

29. A poly-4-hydroxybutyrate biomass produced from renewable resources which is suitable as a feedstock for producing gamma-butyrolactone product, wherein the level of poly-4-hydroxybutyrate in the biomass is greater than 50% by weight of the biomass.

30. The biobased gamma-butyrolactone product of claim 27, wherein the gamma-butyrolactone in the product has 100% biobased carbon content.

31. The process of claim 1, wherein product is about 85% by weight or greater based on one gram of a gamma-butyrolactone in the product per gram of poly-4-hydroxybutyrate.