Deformable Container

Abstract

A deformable container that is suitable for dispensing dishwasher machine cleaner in an automatic dishwasher. The container defines an interior volume for a fluid, and includes an outlet fluidly connected to the interior volume. A portion of the container is deformable upon reaching a predetermined temperature to reduce the size of the interior volume for forcing the fluid out from the container via the outlet. A seal at the outlet is openable by the fluid forced from the interior volume when the size of the interior volume is reduced to control the escape of fluid from the container.

Claims

1. A deformable container defining an interior volume for a fluid comprising: an outlet fluidly connected to the interior volume; a first seal at the outlet; and a deformable portion of the container; wherein upon subject to heat at a first predetermined temperature, the deformable portion of the container reduces the size of the interior volume; and wherein the reduction in size of the interior volume is such that if a volume of fluid were contained in the interior volume of the container prior to deformation, upon deformation of the deformable portion of the container, at least a portion of fluid from the interior volume would cause the first seal to open, and thereafter at least a portion of fluid would pass out from the container via the outlet.

2. The deformable container according to claim 1 further comprising a volume of fluid contained in the interior volume of the container; wherein the first predetermined temperature is between 50 C.-75 C.

3. The deformable container according to claim 1, wherein the first seal is operable to open; and wherein upon subject to heat at a second predetermined temperature which is higher than the first predetermined temperature, the deformable portion of the container further reduces the size of the interior volume.

4. The deformable container according to claim 3 further comprising a volume of fluid contained in the interior volume of the container; wherein the first predetermined temperature is between 50 C.-55 C.; and wherein the second predetermined temperature is between 65 C.-75 C.

5. The deformable container according to claim 1 further comprising a frangible seal at the outlet.

6. The deformable container according to claim 1, wherein the first seal is linear.

7. The deformable container according to claim 1 further comprising a plurality of corrugated channels which do not substantially reduce in size when the container reaches the first predetermined temperature.

8. The deformable container according to claim 7, wherein the plurality of corrugated channels are located downstream of the first seal.

9. The deformable container according to claim 1 further comprising a rib which is not substantially deformable when the container reaches the first predetermined temperature.

10. The deformable container according to claim 9, wherein the rib extends around a circumference of the interior volume.

11. The deformable container according to claim 10, wherein the interior volume comprises no sharp edges in a region that is distal to the outlet and that is adjacent the rib.

12. The deformable container according to claim 1 further comprising a region proximal to the outlet which defines a concave indentation for assisting with the removal of fluid from the container when the container reaches the first predetermined temperature; and wherein the concave indentation defines a flow path for the fluid to the outlet which decreases in cross-section towards the outlet.

13. The deformable container according to claim 1, wherein the interior volume comprises two or more smaller volumes which are fluidly isolated from each other prior to the container reaching the first predetermined temperature.

14. The deformable container according to claim 1, wherein the interior volume is less than or equal to 300 ml prior to the container reaching the first predetermined temperature.

15. The deformable container according to claim 1, wherein the size of the interior volume is operable to reduce by between 70%-90% when the container reaches the first predetermined temperature.

16. The deformable container according to claim 1, wherein the deformable portion of the container is made of a shape-memory material.

17. The deformable container according to claim 16, wherein the shape-memory material is a shape-memory polymer.

18. The deformable container according to claim 17, wherein the shape-memory polymer comprises polyethylene terephthalate.

19. The deformable container according to claim 1, wherein the first seal is made of a material selected from the group consisting of polyethylene, polyethylene terephthalate, and polypropylene.

20. The deformable container according to claim 1, wherein the first seal comprises a filleted/chamfered edge which is exposed to the interior volume for assisting with the opening of the first seal when the container is heated to the first predetermined temperature.

21. The deformable container according to claim 2, wherein the fluid comprises an automatic dishwasher liquid detergent.

22. The deformable container according to claim 21, wherein the automatic dishwasher liquid detergent is a dishwasher machine cleaner.

23. The deformable container according to claim 21 further comprising an attachment configured for attaching the container to the interior of an automatic dishwasher.

24. The deformable container according to claim 23 further comprising a rib which is not substantially deformable when the container reaches the first predetermined temperature; wherein the attachment is located on the rib.

25. The deformable container according to claim 1 further comprising a volume of fluid contained in the interior volume of the container; wherein the fluid comprises a dishwasher machine cleaner formulation.

26. (canceled)

27. A method for dispensing a fluid from a deformable container defining an interior volume containing a volume of the fluid, the container including an outlet fluidly connected to the interior volume and a first seal at the outlet, the method comprising: heating the container to a first predetermined temperature; wherein upon a deformable portion of the container being heated to the first predetermined temperature, the size of the interior volume is reduced such that a portion of the fluid from the interior volume opens the first seal and passes out from the container via the outlet.

28. The method according to claim 27 further comprising heating the container to a second predetermined temperature; wherein the size of the interior volume partially reduces at the first predetermined temperature; and wherein the size of the interior volume further reduces at the second predetermined temperature which is higher than the first predetermined temperature.

29. The method according to claim 28, wherein the first predetermined temperature is between 50 C.-55 C.; and wherein the second predetermined temperature is between 65 C.-75 C.

30. A method of manufacturing a deformable container defining an interior volume for a fluid, the container including an outlet fluidly connected to the interior volume and a first seal at the outlet, the method comprising passing two adjacent sheets of material together through sequential heated dies such that the heated dies shape the sheets of material into the shape of the deformable container.

31. The method according to claim 30 further comprising injecting fluid into the interior volume of a partly formed container; wherein the sequential heated dies comprises a first set of heated dies and a second set of heated dies; wherein passing two adjacent sheets of material together comprises: passing the two adjacent sheets of material together through the first set of dies to shape the adjacent sheets of material into the partly formed container comprising the interior volume; passing the partly formed container containing the injected fluid through the second set of dies to shape the partly formed container into the deformable container.

32. (canceled)

Description

DESCRIPTION OF THE FIGURES

[0038] The invention will now be described, by example only, with reference to the accompanying drawings in which:

[0039] FIG. 1 shows a perspective view of a container in accordance with the invention.

[0040] FIG. 2A shows a bottom view of the container of FIG. 1;

[0041] FIG. 2B shows a front side view of the container of FIG. 1;

[0042] FIG. 2C shows a top view of the container of FIG. 1; and

[0043] FIG. 2D shows a side end view of the container of FIG. 1.

[0044] FIG. 3A shows a first stage of operation of the container shown in FIG. 1;

[0045] FIG. 3B shows a second stage of operation of the container shown in FIG. 1; and

[0046] FIG. 3C shows a third stage of operation of the container shown in FIG. 1.

[0047] FIG. 4A shows an image of a container similar to the container shown in FIG. 1;

[0048] FIG. 4B shows an image of the container of FIG. 4A after having been used in an automatic dishwasher;

[0049] FIG. 4C shows an image of the container of FIG. 4B after having been used in an automatic dishwasher and whilst still inside the tray of an automatic dishwasher.

[0050] FIG. 5 shows a table illustrating the effectiveness of various differently shaped containers when heated.

[0051] FIG. 6 shows a cross-section view of a different container in accordance with the invention.

[0052] FIG. 7 shows a front view of a container having a curved weak seal and a close up view of the curved weak seal.

[0053] FIG. 8 shows an image of a weak seal of a container similar to the container shown in FIG. 7.

[0054] FIG. 9 shows a side end view of the container and the fluid-actuated seal of the container.

DETAILED DESCRIPTION

[0055] With reference in particular to FIGS. 1 and FIGS. 2A-2D, there is shown a container 10 for dispensing a fluid. The container is predominately made of a shaped memory-polymer, such as PET, and defines an interior volume 15 for holding a fluid, such as dishwasher machine cleaner. The interior volume is divided into a first and second smaller region 20;25. Each of the two smaller regions is fluidly connected to a plurality of parallel corrugated channels 30 located at the top of the container. The channels 30 act as an outlet for the fluid to escape from the container as will be described, and do not reduce in size when heated.

[0056] Prior to use, the top ends of the plurality of channels 30 are covered by a frangible seal 35 which is operable, in use, to be snapped off or torn off by the user along a fault line 40 extending substantially perpendicular to the direction of the corrugated channels 30.

[0057] Located between the bottom end of the plurality of channels 30 and the interior volume 15 is a fluid-actuated seal 45. The fluid actuated seal 45 extends across the entire width of the parallel corrugated channels 30 and preferably extends in a linear direction 46 which is substantially perpendicular to the direction of the corrugated channels 30.

[0058] In an example the fluid-actuated seal has a width, defined by the distance between the corrugated channels 30 and the interior volume 15, between 1 mm and 3 mm, for example 1.5 mm to 2.5 mm, for example 1.8 mm to 2.2 mm. The seal width may be 1.5 mm, 1.7 mm, 1.9 mm, 2.1 mm, 2.3 mm, 2.5 mm and/or 2.6 mm. The fluid-actuated seal may have a uniform width or the width of the fluid-actuated seal may vary, for example the fluid-actuated seal may have an area with a smaller seal width to provide a non-uniform seal strength.

[0059] In the example illustrated in FIGS. 7 and 8 the fluid-actuated seal 45 comprises a curved contour. As shown in FIG. 8 the weak seal comprises a first curved contour 47 located between the plurality of channels 30 and the interior volume 15 of the first smaller region 20 and a second curved contour 48 located between the plurality of channels 30 and the interior volume 15 of the second smaller region 25. The first curved contour 47 directs the fluid towards a first apex 47a and the second curved contour 48 directs the fluid towards a second apex 48a so that the internal pressure is greater and the seal starts to open at this point. In the example illustrated in FIGS. 7 and 8 the apex of first and second curved contours 47;48 comprises a discontinuity in the curvature i.e. the apex 47a;48a defines a single point.

[0060] In the example illustrated in FIGS. 7 and 8 the width of the seal is non-uniform. The width of the seal is less close to the apex of the curve. The reduction in the width of the seal weakens the seal at this point relative to the wider seal. The narrower weaker seal requires a lower pressure to open compared to the wider seal. In the example illustrated the seal width gradually declines away from the apex of the curve. The width of the seal may be 3 mm away from the apex and 2 mm at the apex of the curved contours 47;48.

[0061] The fluid-actuated seal may also have a chamfered edge. As illustrated in FIG. 9 the fluid-actuated seal 45 may have a chamfered edge 51 located adjacent to the first and second smaller region 20;25. The chamfered edge gradually increases the seal pressure from the outer edge between the interior volume 15 to the centre of the seal 45 and therefore reduces the initial peeling force so that fluid pressure required to open the fluid-actuated seal is reduced.

[0062] Each of the first and second smaller region 20;25 comprises a front side wall 50 and a rear side wall 55 which are deformable when heated to a predetermined temperature. A strengthening rib 60, which does not substantially deform when heated to this predetermined temperature, and which preferably has a greater thickness than the front side wall 50 and the rear side wall 55, extends around the side and top portions of the interior volume 15 to provide rigidity to the container 10 at the predetermined temperature.

[0063] A partitioning rib 65, having similar properties to the strengthening rib 60, extends from the fluid-actuated seal 45 to the bottom of the container 10 to isolate the first smaller region 20 from the second smaller region 25.

[0064] A fluid port 80 is provided at the top of each the first and second smaller region 20;25 to allow fluid to be inserted therein during the forming process of the container 10 as will be described.

[0065] The container 10 is also provided with attachment means, shown in FIG. 1 as hook shaped portions 71 in the strengthening rib 60, for allowing the container 10 to be attached in an upright position to an object, although more preferably between the supports of a dishwasher tray when the container 10 is located in an inverted position inside a dishwasher, as will be described.

[0066] Operation of the container 10 shown in FIG. 1 and FIGS. 2A-2D is described with reference to FIGS. 3A-3C, and also FIGS. 4A-4C.

[0067] Initially, a user grips the container and snaps off the frangible seal 35 along the fault line 40 (see FIG. 3B). Although not shown in the Figures, rather than being snapped off, the frangible seal 35 may take the form of a tear-off strip which tears along the fault line 40. Once the frangible seal 35 is removed, this exposes the plurality of parallel corrugated channels 30. The exposed top surface from these channels 30 forms the outlet 70 through which fluid can escape from the container 10.

[0068] Once the outlet 70 is formed, the container 10 is then inverted and placed between the supports of a dishwasher tray, as shown in FIG. 3C, and such that the hook shaped portions 71 engage against the bottom of the dishwasher tray (see FIG. 4C). In this inverted position, fluid contained in the first and second smaller region 20;25 is prevented from passing to the outlet 70 via the corrugated channels 30 by the fluid-actuated seal 45, which at this stage remains closed.

[0069] The dishwasher is then operated with the container 10 located inside.

[0070] As the interior of the dishwasher heats up, the heat generated within the dishwasher causes the deformable container to heat up. In the case of a container made of PET, once the container reaches a temperature of approximately 50 C.-55 C., the front side wall 50 and the rear side wall 55 of the container deform slightly inwardly. The initial deformation of these side walls 50;55 causes the size of the first and second smaller region 20;25 to reduce, which increases the pressure of the fluid contained within these regions 20;25.

[0071] The increased pressure of the fluid exerts a pressure on the fluid-actuated seal 45 which forces it to peel open, allowing an initial portion of the fluid from the container 10 to pass through the channels 30 and out the outlet 70 into the dishwasher.

[0072] As the interior temperature inside the dishwasher continues to increase towards the intended operating temperature of the dishwasher, typically around 65 C.-75 C., the increase in temperature causes further inward deformation of the front side wall 50 and the rear side wall 55 of the container 10 such that the container is deformed into a flattened state as shown in the images of FIG. 4B and FIG. 4C. In this state, any fluid in the interior volume is forced by the flattened side walls 50;55 through the fluid-actuated seal 45 and out of the outlet 70. In this flattened state shown in FIGS. 4B and 4C, the interior volume of the container is around 10%-30% of its original size as shown in FIG. 4A.

[0073] It will be seen from FIG. 4C that the hook shaped portions 71 in the strengthening rib 60, which engage against the bottom of the dishwasher tray, help keep the container in its inverted position, even when it is deformed. This is important since fluid escape from the container is optimized when the container is in an inverted position as shown in FIG. 4C, rather than in a flat position. The hook shaped portions 71, when engaged against the bottom of the dishwasher tray also keep the container straight in use and prevent it from folding like a book onto itself when it deforms. Such folding is disadvantageous since it reduces the amount of fluid which can escape from the first and second smaller regions 20;25. The hook shaped portions 71 also prevent the container 10, once emptied and deformed, from being displaced inside the dishwasher by the pressurized water jets emitted from the rotating spray arm of the dishwasher.

[0074] The extent to which fluid is forced out from the first and second smaller region 20;25 depends on the shape of the first and second smaller region 20;25, and the extent to which the front side wall 50 and the rear side wall 55, which are made of a shaped-memory polymer, inwardly deform when they are heated to the predetermined temperature.

[0075] To improve the extent to which fluid inside the first and second smaller region 20;25 is drawn towards the channels 30, the regions of the front side wall 50 and the rear side wall 55 which are away from the outlet 70 and which are proximal to the strengthening rib 60 and the partitioning ribs 65 should comprise no sharp edges, since these sharp edges when deformed can create narrow capillaries which retain fluid inside the first and second smaller region 20;25, even after these regions 20;25 have deformed. To minimize such fluid retention inside the first and second smaller region 20;25, preferably the regions of the front side wall 50 and the rear side wall 55 which are proximal to the strengthening rib 60 and the partitioning ribs 65 comprise a fillet 90.

[0076] To further improve the extent to which fluid inside the first and second smaller region 20;25 is drawn towards the channels 30, each of the front side wall 50 and the rear side wall 55 may comprise a concave indentation 75 in a region proximal to the channels 30 and the outlet 70 which decreases in cross-section towards the outlet, and which does not deform when heated. FIGS. 4A-4C show this most clearly, where it can be seen that the concave indentations 75 have the same shape both before and after the container 10 has been heated and deformed in an automatic dishwasher.

[0077] Having the fluid-actuated seal 45 formed in a straight line, rather than as a curve, also results in improved transfer of fluid from the first and second smaller region 20;25 through to the channels 30.

[0078] To illustrate how the shape of the first and second smaller regions 20;25 affects how these regions deform and expel fluid when heated, FIG. 5 shows various differently shaped deformable containers before and after use inside an automatic dishwasher operated at 65 C. As can be seen in FIG. 5, the pillow shaped container having the concave indentations 75 and the fillet 90 is the most effective of the shown containers at expelling fluid.

[0079] Although the deformable container shown in the Figures has been described as being suitable for dispensing dishwasher machine cleaner in an automatic dishwasher, it will be appreciated that the container may be modified for use in any situation where a fluid requires dispensing in an environment only when the temperature of the environment reaches a predetermined level. One such situation includes dispensing detergent inside a washing machine.

[0080] The choice of shape-memory polymer for the deformable portions of the container 10 will depend on the intended application for the container 10. When used inside a dishwasher, the deformable portions of the container 10 are preferably predominately made of a shape-memory polymer which has a glass transition temperature (T.sub.G) in the region of the operating temperature inside a dishwasher. Accordingly, for use inside a dishwasher, the selected shape-memory polymer should have a glass transition temperature of between 50 C.-75 C. PET is one such suitable shape-memory polymer.

[0081] Once the choice of shape-memory polymer has been made for the container 10, manufacture of the container 10 is achieved by heating the container above its glass transition temperature and then shaping the container in these conditions, for instance in a thermoforming process or a stretch blow moulding process, into a stressed shape. Importantly, the portions of the container that are stressed in the forming process are the portions of the container that are intended to be deformed in use of the container. These portions include the front side wall 50 and a rear side wall 55; but not the partitioning rib 65, the strengthening rib 60, or the concave indentations 75. Once the stressed shape is achieved the container 10 is constrained in this stressed shape and simultaneously cooled back below its glass transition temperature. Once cooled, the container 10 is set in the stressed shape, which is the shape shown in FIG. 1 and FIGS. 2A-2D.

[0082] When the container 10 is subsequently heated above its glass transition temperature in use, e.g. inside a dishwasher, the container 10 is allowed to revert to a shape which is less stressed. This less stressed shape corresponds to the shape of the container when it is inwardly deformed.

[0083] From the above, it will be appreciated that how the container 10 is manufactured, and placed in a stressed shape, affects the extent to which the container inwardly deforms when it is heated to the predetermined temperature. It will therefore be appreciated by the skilled person that the exact material selected (together with its associated glass transition temperature) for the container, and the particular manufacturing conditions used to shape the container in its stressed shape, will thus vary depending on the intended application for the container.

[0084] The forming process used to create the container 10 can be performed in a number of different ways, as required, to allow for fluid to be inserted into of each the first and second smaller region 20;25. In one forming process, the container 10 is formed by passing two adjacent sheets of material through a series of sequential heated dies, wherein each heated die operates to partly shape the sheets of material into the shape of the container 10. In one operation, the adjacent sheets of material are passed through a first set of heated dies such that the sheets form the container 10 but without its fluid ports 80 sealed. From this partly-formed state, the partly-formed container is placed in an upright position and fluid is then inserted into each of the first and second smaller regions 20;25 via the unsealed fluid ports 80. Once the container is filled, the partly-formed container is passed through a further set of heated dies to seal the fluid ports 80 such to seal the fluid inside the first and second smaller regions 20;25, and such to create the container 10.

[0085] In relation to the faces of the portions of the heated dies which form the adjacent sheets of material into the strengthening rib 60, and any partitioning rib 65, preferably these faces are textured, such as corrugated. In this way, when these faces from the heated dies contact the portions of material which form the strengthening rib 60 (and any partitioning rib 65), the die faces deform these portions of material such they share a greater area of contact compared with if they were formed using non-textured die faces. This additional contact area improves the sealing properties of the strengthening rib 60 and the partitioning rib 65.

[0086] It will be appreciated that various modifications can be made to the container herein described. For instance, it will be appreciated that rather than the interior volume of the container being made of two isolated regions 20;25, the interior volume may be separated into any number of such regions (including only one) depending on the number of partitioning ribs 65 (if any) used.

[0087] The size of the container 10 and its interior volume 15 may also vary depending on the intended application for the container 10. When being used to hold dishwasher machine cleaner, the interior volume may ideally hold no more than 300 ml, preferably no more than 250 ml, and further preferably no more than 200 ml, of dishwasher machine cleaner.

[0088] The dimensions of the container may also vary depending on the intended application for the container 10. When being intended for use in an automatic dishwasher, the maximum height of the container may be approximately 135 mm, the maximum width of the container approximately 150 mm, and the maximum depth of the container approximately 35 mm.

[0089] The reduction in size of the interior volume need not necessarily be achieved using a shape-memory material. A similar reduction in size may be achieved using a bag-in-box type container as shown in FIG. 6. In this arrangement, the container 100 may be provided with a rigid outer housing 102 in which is located a resilient container 104 defining an interior volume for a fluid to be dispensed. A fluid-actuated seal 145, which may be similar to the fluid-actuated seal 45 described in FIG. 1 and FIGS. 2A-2D, provides an outlet for the fluid from the resilient container 104. A heat-transfer fluid 103 (such as air), which expands when heated, is located between the rigid outer housing 102 and the resilient container 104.

[0090] In operation of the container 100 shown in FIG. 6, when the container 100 is heated to the predetermined temperature, the heat-transfer fluid between the rigid outer housing 102 and the resilient container 104 expands causing the resilient container 104 to inwardly deform, which increases the pressure of the fluid inside the resilient container 104. As the pressure exerted on this fluid increases, the pressure this fluid exerts on the fluid-actuated seal 145 also increases. Ultimately, the pressure on the fluid-actuated seal 45 forces it to open, allowing fluid out of the container 100.