COMPOSTABLE CONTAINER FOR STORING FLUIDS
20170362005 · 2017-12-21
Inventors
- Cynthia Tolibas-Spurlock (Burlingame, CA, US)
- Bambi Allred-Forsman (Chehalis, WA, US)
- Darla Agnew-Von Moos (Chehalis, WA, US)
Cpc classification
Y10T156/1059
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B9/02
PERFORMING OPERATIONS; TRANSPORTING
B32B29/06
PERFORMING OPERATIONS; TRANSPORTING
B65D1/0207
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/1348
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B29L2031/712
PERFORMING OPERATIONS; TRANSPORTING
Y02W90/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B29/002
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/1303
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B65D65/466
PERFORMING OPERATIONS; TRANSPORTING
B32B5/24
PERFORMING OPERATIONS; TRANSPORTING
B29K2995/0056
PERFORMING OPERATIONS; TRANSPORTING
B29K2995/006
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65D65/46
PERFORMING OPERATIONS; TRANSPORTING
B32B23/04
PERFORMING OPERATIONS; TRANSPORTING
B32B5/24
PERFORMING OPERATIONS; TRANSPORTING
B32B29/00
PERFORMING OPERATIONS; TRANSPORTING
B65D5/06
PERFORMING OPERATIONS; TRANSPORTING
B32B9/02
PERFORMING OPERATIONS; TRANSPORTING
B32B29/06
PERFORMING OPERATIONS; TRANSPORTING
B65D1/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A fully compostable container is provided having an enclosed body with an opening through an interior surface and an exterior surface. The enclosed body having a plant fiber structural layer configured to biodegrade in ambient conditions into nontoxic residue and a fluid barrier layer formed on a first side of the structural layer to form the interior surface of the enclosed body, the fluid barrier layer configured to biodegrade in ambient conditions into nontoxic residue. The container is gradually biodegradable when exposed to a set of factors in a natural environment and has a shelf life of six months when stored under standard commercial conditions.
Claims
1. A cap for an ambient compostable container, comprising: a first end that is open and is configured to be coupled to sidewalls of the container; a second end that is closed that prevents fluid from passing through the first end and through the cap when the cap is coupled to the container; and a cap sidewall that extends from the first end to the second end, each of the first end, the second end, and the cap sidewall being formed from an ambient compostable material that is configured to degrade into nontoxic residue in ambient environmental temperatures in the range of 20 and 30 degrees Celsius.
2. The cap of claim 1, wherein the cap has a shelf life of approximately six months.
3. The cap of claim 2, wherein during the shelf life, the cap is substantially insoluble and temperature resistant.
4. The cap of claim 1, wherein the cap is made of a potato starch.
5. A device, comprising: a cap formed from an ambient compostable material configured to degrade into nontoxic residue in ambient environmental temperatures in the range of 20 and 30 degrees Celsius, the cap having: a first end that is open; a second end that is closed; and a sidewall having a substantially cylindrical shape, the sidewalls extending from the first end to the second end.
6. The device of claim 5, wherein the cap has a shelf life of approximately six months.
7. The device of claim 6, wherein during the shelf life, the cap is substantially insoluble and temperature resistant.
8. The device of claim 5, wherein the cap is made of a potato starch.
9. The device of claim 5, wherein the cap is configured to couple to a mouth of a container and form a fluid tight seal.
10. A system, comprising: a first portion formed from an ambient compostable material that is configured to degrade into nontoxic residue in ambient environmental temperatures in the range of 20 and 30 degrees Celsius, the first portion including: a first seal portion; and a first recess; and a second portion formed from an ambient compostable material that is configured to degrade into nontoxic residue in ambient environmental temperatures in the range of 20 and 30 degrees Celsius, the second portion including: a second seal portion; and a first protrusion that is configured to nest in the first recess.
11. The system of claim 10, further comprising a container, wherein the first and the second seal portions are configured to combine to form a fluid tight seal with an opening of the container.
12. The system of claim 11, wherein the first portion further includes a second protrusion corresponding to the first recess.
13. The system of claim 12, wherein the second protrusion is configured to form a fluid tight seal with the opening of the container.
14. The system of claim 11, wherein the first portion further comprises an inlet cutout configured to couple the cap to the container.
15. The system of claim 11, wherein the second portion further comprises an inlet cutout configured to couple the cap to the container.
16. The system of claim 11, wherein the first and second seal portions are configured to combine to form the fluid tight seal when the first protrusion nests in the first recess.
17. The system of claim 10, wherein the first portion and the second portion are formed of a structural fiber material blended with a fluid resistant resin.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0018]
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DETAILED DESCRIPTION
[0030] In the following description, certain specific details are set forth in order to provide a thorough understanding of various embodiments of the disclosure. However, one skilled in the art will understand that the disclosure may be practiced without these specific details. In other instances, well-known structures associated with techniques for manufacturing containers have not been described in detail to avoid unnecessarily obscuring the descriptions of the embodiments of the present disclosure.
[0031] Unless the context requires otherwise, throughout the specification and claims that follow, the word “comprise” and variations thereof, such as “comprises” and “comprising,” are to be construed in an open, inclusive sense, that is, as “including, but not limited to.”
[0032] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0033] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
[0034] In the drawings, identical reference numbers identify similar elements or acts. The size and relative positions of elements in the drawings are not necessarily drawn to scale.
[0035]
[0036] All of the components used to manufacture and assemble this container 2 are biodegradable in ambient conditions into nontoxic constituents. More particularly, the container 2 is compostable in the average family's backyard, under normal outdoor weather conditions. The term biodegradable is intended to encompass the degradation of material from naturally occurring microorganisms, such as bacteria, fungi, or algae, over a period of time in natural conditions. Composting is a natural process that turns organic materials into a substance often called humus. Fertile soil is rich in humus, providing a reservoir of stabilizing material that imparts beneficial physical, chemical, and biological properties to soil. Composting occurs through the aerobic activity of microorganisms that require oxygen, moisture, and food in order to thrive. These conditions can be achieved in backyard compost bins or piles. As the microorganisms grow they produce heat, water, and carbon dioxide, while transforming the starting materials into compost that can be used as a stable soil conditioner.
[0037] Composting in a backyard is achieved in ambient conditions that include temperature, pressure, and moisture, to name a few. The container 2 will decompose in a consumer's backyard into compost without applying additional heat or extensive monitoring of the composting process. Ambient temperature for backyard composting is in the range of 20-30 degrees Celsius (65-90 degrees Fahrenheit). Some prior art containers advertise as being “biodegradable,” but in fact, all such containers require special treatment and commercial compositing facilities to begin the biodegradation process. These containers will not biodegrade on their own under normal outdoor conditions. In contrast to the present invention, commercial composting facilities require maintained temperatures above 60 degrees Celsius, usually over 150 degrees Fahrenheit, careful monitoring of moisture, and regulation of the microorganisms. These commercial facilities regularly aerate and turn the compost, regulate the airflow, and balance the nitrogen and carbon containing materials. The additional heat and careful monitoring are expensive and time consuming. In addition, the commercial compositing facilities rely on consumers to recycle the products. If a biodegradable product is not recycled to a commercial facility, the product remains in a landfill for many years before the decomposition process naturally begins. Accordingly, a container that is compostable under normal conditions is quite different from a container that is called “biodegradable” or is compostable in a commercial system.
[0038] As the inventive container 2 biodegrades naturally, no harmful chemicals or metals are left behind. The container 2 will decompose into water and organic matter; the combined residues of organic materials that have lost their original structure will then undergo rapid decomposition into simpler ingredients.
[0039] As a result of decomposing into nontoxic residues, the container 2 and its associated components, like the mouth 14 and the cap 16, can be composted anywhere. A consumer can compost container 2 in their backyard or they can throw it away. The container 2 will decompose into nontoxic residues in landfills or along the side of a highway. These nontoxic residues are beneficial to plants and the environment. Importantly, the constituent materials used to manufacture the container 2 will not diminish the value or utility of the compost or humus when the container 2 degrades.
[0040]
[0041]
[0042] The first side 8 of the structural layer 18 is covered by a fluid barrier layer 10 that forms an interior surface 26 of the body 6. The fluid barrier layer 10 may be substantially thinner than the structural layer 18. The second side 20 of the structural layer 18 forms an exterior surface 24 of the body 6. The interior surface 26 protects the structural layer 18 from fluid 4 stored in the body 6. The second side 20 of this structural layer 18 is not covered with any additional insulating layers and hence is directly exposed to its immediate environment. The absence of a resistance to outdoor conditions increases its breakdown when placed in natural environmental conditions. In contrast, if placed in standard commercial distribution conditions, such as on a warehouse shelf, in a retail store, or stored at home in a substantially dry and room temperature setting, the structural layer 18 is capable of having a long lasting shelf life that can amount to several months to a few years. The selected structural layer 18 is one that has excellent mechanical strength and durability when dry, but when wet, will rapidly degrade over a matter of days. In addition, the structural layer 18 may break down more quickly when subjected to direct UV rays from the sun.
[0043] An opening 22 is formed through the fluid barrier layer 10 and the structural layer 18. The mouth 14 attaches to the opening 22 and forms a watertight seal. The mouth 14 cooperates with the fluid barrier layer 10 to create the seal to prevent moisture from interacting with the structural layer 18.
[0044] The container 2 can be formed by a single sheet of the structural layer 18 that is then coated or laminated with the fluid barrier layer 10. Subsequently, the single sheet is cut and manipulated to form the body 6 having the opening 22 through the fluid barrier layer 10 and the structural layer 18. The mouth 14 may be coupled to the opening 22 before or after the body 6 is constructed.
[0045] According to various embodiments of the present invention, the compostable container 2 can be fixed into different shapes.
[0046]
[0047]
[0048] The structural layer 18 may be formed of a plant-based fiber that can be manipulated to form a rigid structure. Fibers or pulp from sugarcane, bagasse (fiber waste after sugarcane stalks are crushed to extract the juice), wood, bamboo, molded pulp, or recycled paper or slurry can be manipulated to form the structural layer 18. Alternatively or additionally, starch-based materials can be included to form the rigid structural layer 18. The material used for the structural layer 18 degrades naturally having an adequate level of inherent biodegradation and no adverse impact on the ability of composts to support plant growth. More particularly, the materials do not include any petroleum-based plastic fibers, plastic polymers, or other petroleum-based products.
[0049] Fiber or pulp-based products can be manufactured in a variety of ways. Thick-walled products have walls in the range of 3/16 to ½ inches in thickness with a rough side and a relatively smooth side. Inexpensive single pass molds may be used to form containers from mixed recovered paper and craft paper slurries. Transfer molded products have thinner walls in the range of 1/16 to 3/16 inches. The process uses transfer molds that produce a relatively smooth surface on a first side and a smoother surface on a second side. Alternatively, thermoformed fiber products are thin-walled. The product is cured while it is still in the mold. This process produces strong, smooth-surfaced molded pulp products. An additional method of manufacture is processed molded pulp products. The thick-walled, transfer molded, and thermoformed fiber products undergo a secondary processing after the basic production process. Secondary processes include coating, printing, hot-pressing, die-cutting, trimming, or coloring.
[0050] Starch-based products include corn, maize, wheat, cassava, potato, or potato and tapioca blend. These products can be formed by a variety of methods, including compression forming, foaming, and injection molding. The starch content of these starch-based products should exceed 60% to achieve more significant material breakdown. Higher starch content products degrade more quickly and create less recalcitrant residues. Many starch-based polymers are blended with high-performance polymers to achieve necessary performance. However, these high-performance polymers can degrade into undesirable residues. Starch-based products may be incorporated into the structural layer 18 or the fluid barrier layer 10, if nontoxic residues remain after the container breaks down. Some starch products that may be incorporated into the structural layer are thermoplastic starch products, starch synthetic aliphatic polyester blends, starch and polybutylene succinate blends, starch and polybutylene succinate adipate blends, and starch polyvinyl alcohol blends.
[0051] The fluid barrier layer 10 is biodegradable and formed from non-petroleum-based materials. For example, the fluid barrier layer 10 may be formed of cellulose acetate products, i.e., wood pulp. The cellulose acetate products can be heat sealed to offer gas barrier properties and can be tailored to achieve a range of moisture barrier properties. These products can be used for lamination on the structural layer 18. Alternatively or additionally, products made from whole grain cereals, such as those produced by Biolice, may be used to form the fluid barrier layer 10. Extrusion equipment can be used to manipulate Biolice products.
[0052] Zein, a corn gluten product, may also be used for the fluid barrier 10. Zein is a prolamine protein found in corn that is manufactured into a powder. The powder can be manipulated to form film coatings that have moisture resistant properties. The zein powder can also be manipulated to form resins and other polymers that can be extruded or rolled into a variety of products.
[0053] Bioplastics refer to two different types of plastics: plastics based on renewable resources, and biodegradable and compostable plastics. Not all bioplastics degrade into nontoxic residues that are environmentally benign. In addition, some bioplastics will degrade only in commercial composting facilities. Bioplastics that undergo degradation by natural biological processes to yield carbon dioxide, water, inorganic compounds, and biomass, may be used in the formation of the components of the container 2.
[0054] As an alternative, the fluid barrier layer 10 may be a coating where only a minimal amount of biodegradable polyester is necessary to provide an isolating layer between the structural layer 18 and the fluid 4 held within the container 2. Moreover, the thin structure of the fluid barrier 10 also allows for a more rapid biodegradation. Due to its low mass it contains less resistance to biodegradation, thereby enabling a more efficient breakdown of the organic matter when exposed to natural environmental conditions. In one embodiment, the biodegradable polyester material of the fluid barrier layer 10 has a shelf life of at least six months in a standard commercial environment, and during its shelf life is insoluble in fluids and substantially exhibits a temperature resistance. During this time, the fluid barrier layer 10 provides a proper isolating layer between the structural layer 18 and the fluid 4. Subsequent to the expiration of the at least six months, the fluid barrier layer 10 becomes vulnerable to biodegradation, if in direct contact with fluids or situated in natural environmental conditions. In effect, after six months the fluid barrier layer 10 becomes soluble and subject to temperature conditions.
[0055] If exposed to the outdoor weather and environment, the container 2 will degrade rapidly. As noted, if it is holding a fluid 4, the fluid barrier layer 10 keeps the fluid 4 from degrading the structural layer 18. However, if fluid is applied to the outside of the container 2, then it will loose its mechanical strength and fall apart. The structural layer 18 may pull apart the fluid barrier layer 10 into many pieces, since the fluid barrier layer 10 does not have sufficient support for itself. The fluid barrier layer 10, once ripped or torn into many pieces, will be subject to weather from all sides. These pieces are now exposed to all weather elements on all sides and will degrade rapidly, perhaps over several days instead of weeks that would be required if the fluid barrier layer 10 remained intact.
[0056] As a further embodiment, the fluid barrier layer 10 can be quite strong and fluid resistant, but degrade rapidly, if exposed directly to infrared or UV light emitted by the sun. Since the fluid barrier layer 10 is situated only in the interior of the container 2, it will neither be exposed to sunlight nor in most conditions to artificial light. Once the structural layer 18 degrades, the fluid barrier layer 10 is exposed to sunlight, which will cause the fluid barrier layer 10 to biodegrade rapidly.
[0057] In one embodiment, a material is provided within fluid barrier layer 10 that is not affected by light from standard artificial light, such as from incandescent bulbs, fluorescent bulbs, halogen bulbs or the like. It is known that sunlight emits particular wavelengths that are not found in standard artificial lighting, most of which are in the UV A or UV B range of light. A material which is sensitive to particular sunlight emissions, but is resistant to artificial light, can be part of the fluid barrier layer 10 so that the fluid barrier layer 10 remains fully intact for a long shelf life, but once exposed to sunlight biodegrades rapidly.
[0058] The mouth 14 of the container 2 as well as the cap 16 thereto may also be made of biodegradable material based on potato starch as described with biodegradable material used for the fluid barrier layer 10. The mouth 14 and cap 16 may have the same biodegradation properties as the fluid barrier layer 10, in which case they will have a shelf life of at least six months in a standard commercial environment. During this period, the mouth 14 and the cap 16 will be substantially insoluble and temperature resistant. Alternatively, they may have different biodegradation properties, since both elements are only occasionally in contact with the fluid 4 stored in the container 2 and hence might not necessitate the same high insolubility and fluid or temperature resistance.
[0059]
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[0061]
[0062] Prior to processing, the materials used to form the structural layer 18 and the mixed structural and fluid barrier layer 30 can be pelletized resins molded together with additives, liquid resins, pulp slurries, powders, or woven components. These pre-processed materials can be manipulated to form the container 2 by injection molding, blow molding, blown film extrusion, vacuum forming, and compression molding. The fluid barrier layer may be attached or formed simultaneously during these processes. Alternatively, the fluid barrier layer may be formed after the structural layer by lamination or spray manufacturing techniques.
[0063]
[0064] The body 52 has a base 56 that may be formed to provide a substantially flat stable surface on which the container 50 may stand in a substantially vertical position. The body 52 has a lower portion 58 of a fluid chamber 60 that is larger than an upper portion 62. The upper portion 62 has a substantially oval cross section and forms an opening 64 (see
[0065]
[0066]
[0067]
[0068] The first portion 66 is illustrated on the left side of the multipurpose lid 54. The first oval protrusion 70 extends from a first surface 72 of the first portion 66 and positioned above the seal portion 74a.
[0069]
[0070]
[0071] The first portion 66 may be retained for future use. The body includes a cutout region 86 that is configured to cooperate with an inlet cutout 88 on the first portion 66. The second portion 68 also includes the inlet cutout 88. The inlet cutout is configured to couple the portion 66, 68 to the cutout region 86.
[0072]
[0073] While other systems require higher production costs and necessitate certain commercial conditions, the present invention offers a cost and process effective product. Not only does the present invention offer a cost effective production enabling competitive pricing of the container 2, 50, but it also eliminates the necessary processing associated with the recycling of plastic waste. Waste management collection and processing of the container 2, 50 is not necessary, since it can biodegrade in the natural environmental conditions of a person's garden, backyard, lawn, compost bin, etc. As such, specific commercial composting conditions for plastic waste are also no longer necessary, since the properties of the container 2, 50 are configured such that all elements are subject to biodegradation after at least six months, when exposed to natural environmental conditions.
[0074] Moreover, eliminating the need for recycling containers will enable individuals in regions that do not supply recycling mechanisms to conveniently switch away from petroleum-based plastic containers. Since the container 2, 50 is completely biodegradable, the burdensome separation of various elements in the waste management process, in accordance to whether they are biodegradable, can be avoided. For example, there is no longer a need to separate the body 6 from the cap 16, since both are completely biodegradable. It should also be considered that even if individuals choose not to recycle, the container 2, 50 will biodegrade in natural environmental conditions. Accordingly, even if the container 2, 50 reaches water systems or other natural habitats, the usual harm caused by plastic waste will be eliminated, since the container 2, 50 can easily biodegrade within those conditions.
[0075] The above descriptions are merely exemplary embodiments for implementing the present invention, so that the present invention is not limited thereto. The true scope of the present invention should be defined to the extent that those skilled in the art can make various modifications and changes thereto without departing from the scope of the invention, as defined by the appended claims.
[0076] The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet, are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.
[0077] In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.