WO2020264564A1

WO2020264564A1 - Compostable container

Info

Publication number: WO2020264564A1
Application number: PCT/US2020/070180
Authority: WO
Inventors: Roy SEGAL; Idit HOTER-ISHAY; Arik Yuval
Original assignee: Innogmatics Ltd
Current assignee: Innogmatics Ltd
Priority date: 2019-06-28
Filing date: 2020-06-25
Publication date: 2020-12-30
Anticipated expiration: 2021-12-28

Abstract

A compostable container has a front face, back face, left wall, right wall, satchel bottom, container opening near the top and a carrying handle above the container opening. The compostable container is made from compostable materials, such as kraft paper or cardboard. The interior of the compostable container may be coated with a compostable water-resistant coating. The container is structured and creased such that it can be folded flat for shipment and then unfolded for use.

Description

Title of Invention:

Compostable Container

Technical Field:

The inventions described herein are in the field of compostable containers.

Background Art:

There is a long felt need for compostable containers that are suitable for wet materials such as food waste. As used herein, "compostable" means a material that can be metabolized to a safe and sanitized product. Materials that meet the European standard EN 13432 are considered compostable. Containers suitable for wet materials include, but are not limited to, trash cans, garbage cans, waste bins, dustbins, rubbish baskets and other containers that can serve as a bin bag, waste bag, or trash bag.

An example of a compostable material is paper, such as kraft paper. Kraft paper is used to make paper bags and cardboard. Paper bags and cardboard can be used to make compostable containers. Kraft paper by itself, however, is mechanically degraded by exposure to moisture. This effect can be reduced by coating kraft paper with a moisture resistant polymer. Compostable moisture resistant polymers include polylactic acid (PLA), polybutylene adipate terephthalate (PBAT) and FlexSHIELD™ coatings produced by Cascades Sonoco.

Figure 1A is a photograph of a prior art compostable container 100 suitable for holding wet materials, such as food waste 102. This is a food waste bag produced by Obeo Ltd. The prior art compostable container comprises: a) a paper bag 104 with a water-resistant coating 122 on its interior surface; and

b) a cardboard shell 106.

The cardboard shell is a piece of cardboard that comprises a closure flap 112, a back face 116, a bottom 118 and a front face 122. The paper bag is joined to the cardboard shell. The side walls 108 of the prior art compostable container are paper and hence they have reduced strength relative to the cardboard. This limits how much weight of food waste can be put in the container.

The closure flap comprises a closure tab 114. The front face comprises a closure slot 124 on its upper portion. In operation, the prior art compostable container is opened such that the closure flap is away from a container opening 126 formed by the paper bag. A user may then place food waste in the container.

Figure IB is a photograph of the prior art compostable container 100 after the container has been filled with food waste. The user has bent the closure flap 112 over the container opening. The user has then engaged the closure tab 114 with the closure slot 124 to keep the container closed.

In order to carry the closed container to a disposal bin, the user may grip the closure flap 112 and lift the container. If the container is heavy, the closure tab may disengage from the closure slot allowing the container to open and possibly cause food waste to spill out. The weight of the filled container may also cause excessive strain 134 on a first hand 132 of the user that the user is using to grip the closure flap. Users with a weak grip may need to use a second hand 136 to hold the bottom of the container.

There is need, therefore, for a compostable container that a user can lift with one hand once it is full without causing the closure flap to open or require a particularly strong grip.

Summary of Invention:

The summary of the invention is a guide to understanding the invention. It does not necessarily describe the most generic embodiment.

Figure 2B is a front left top perspective drawing of an improved compostable container 200 that can be lifted by a user with one hand after it is full without causing a closure flap 214 to open and without requiring the user to have a particularly strong grip. The compostable container comprises: a) a front face 202; b) a back face 204; c) a left wall 208; d) a right wall 206; e) a satchel bottom 212; f) a container opening 210 (indicated by a broken line) on an upper portion of said compostable container; and g) a carrying handle 228 comprising a handle opening 232 located above said container opening wherein: h) said left wall, said right wall and one or more of said back face and said

satchel bottom comprise one or more creases 222, 224 such that said compostable container can be collapsed to fold flat and opened to comprise an internal volume 201 for receiving material, such as wet trash or other trash; and i) said compostable container comprises a sheet of material that is compostable, such as kraft paper cardboard, with an optional compostable moisture-resistant coating, such as one or more of PLA, PBAT or

FlexSHIELD™.

The creases 222 on the walls may be arranged to form a front pleat 232, a back pleat 236 and a lower gusset 234 on each wall. Thus, when a user pushes said walls inward, the bottom 212 will fold up about the back crease 224 and the container will fold flat. Folding the container flat will reduce shipping and storage costs. In order to set the compostable container up after shipping, the user may pull the satchel bottom down and the walls will quickly and conveniently expand out. The user may collapse the container into its folded configuration and open it to its set-up configuration as many times as desired. Figure 3 is a front left top perspective view of the compostable container 200 in said folded configuration. The back face 204, left wall 208, satchel bottom 212, back crease 224 and right wall 206 are indicated. Alternative folded configurations may be provided. For example, a crease may be provided in the bottom 212 so that it may be folded in half.

Referring again to figure 2B, the closure flap 214 may be adapted to cover said container opening 210 and adapted to rotate away from said container opening to allow material to be put into the container.

The closure flap may comprise a closure tab 216 proceeding from a lower edge thereof. The front face may comprise a closure slot 218 for receiving said closure tab such that said closure tab can be inserted into said closure slot and hold said closure flap over said container opening. This might be done by a user when the container is full.

The closure mechanism for the closure flap can be any suitable mechanism, such as glue, magnets, and hook-and-loop fasteners.

The closure flap may comprise a holding tab 238 located on an upper portion thereof. The holding tab may be adapted to engage a holding portion of said compostable container such that said closure flap will remain open and away from said container opening. This will allow a user to place materials through the opening and into the compostable container. A holding portion may be an edge 230 of the handle opening.

Figure 2D is a left elevational drawing of the compostable container 200. The front face 202 and back face 204 may be angled inwardly such that the upper edges thereof may meet and be joined at an apex 246. This will give stability to the container against being knocked over. Each of the front and back face may be at a face angle 242 with respect to vertical. The carrying handle 228 may proceed vertically upward from the apex. Thus, the weight of the material in the container will not cause the closure flap to open when the container is full and lifted up by a user.

Figure 2A is a plan view drawing of the compostable container 200. Figure 2C is a front elevational drawing of the compostable container 200. Each of the left wall 208 and right wall 206 may form a wall angle 244 with respect to vertical. In this embodiment, the wall angle is about zero degrees. Alternatively, the wall angle may be greater than zero degrees for additional side-to-side stability of the container.

A suitable height 266 of the container is about 436 mm. This height will allow an adult person of normal stature to pick up the container and carry it without said person having to bend said person's arm upward.

A suitable width 264 for the container is about 180 mm. A suitable depth 262 of the container is about 180 mm. These measurements provide a container with an internal volume of about 5 liters.

A suitable closure flap width 268 is about 140 mm. A suitable closure flap height 260 is about 140 mm. This will allow a sufficiently large container opening so that a user can readily insert material therethrough. Larger and smaller containers with varying volumes and proportions may be suitable depending upon a particular need. Larger containers may be suitable for larger capacity. Smaller containers may be suitable for tabletop usage.

Figure 4A is a plan view drawing of a compostable container 400 similar to the compostable container 200 but with different overall dimensions. Figure 4B is a front left top perspective drawing of the compostable container 400. Figure 4C is a front elevational drawing of the compostable container of 400. Figure 4D is a left elevational drawing of the compostable container of 400.

A suitable width 464 of the compostable container 400 is 260 mm. A suitable depth 462 is 260 mm. A suitable height 466 is 436 mm. This provides an internal volume 401 of about 11 liters.

A suitable closure flap width 468 is 220 mm. A suitable closure flap height 460 is 140 mm.

Brief Description of Drawings:

Figure 1A is a photograph of a prior art compostable container suitable for holding wet materials, such as food waste. Figure IB is a photograph of the prior art compostable container of figure 1A after the container has been filled with food waste.

Figure 2A is a plan view drawing of a compostable container.

Figure 2B is a front left top perspective drawing of the compostable container of figure 2A. Figure 2C is a front elevational drawing of the compostable container of figure 2A.

Figure 2D is a left elevational drawing of the compostable container of figure 2A.

Figure 3 is a front left top perspective view of the compostable container of figure 2A in a folded configuration.

Figure 4A is a plan view drawing of an alternative compostable container. Figure 4B is a front left top perspective drawing of the compostable container of figure 4A.

Figure 4C is a front elevational drawing of the compostable container of figure 4A.

Figure 4D is a left elevational drawing of the compostable container of figure 4A.

Figure 5 is a photograph of a compostable container similar in design to the compostable container of figure 2A. Figure 6 is a photograph of the compostable container of figure 5 with the closure flap opened.

Figure 7 is a photograph of the compostable container of figure 5 in a folded configuration.

Figure 8 is a plan view drawing of a blank for making the compostable container of figure 5.

Figure 9 is a plan view of a layout of a plurality of the blanks of figure 8 on a board of sheet stock.

Figure 10A is a plan view drawing of an alternative compostable container.

Figure 10B is a front left top perspective drawing of the compostable container of figure 10A. Figure IOC is a front elevational drawing of the compostable container of figure 10A.

Figure 10D is a left elevational drawing of the compostable container of figure 10A.

Figure 11 is a photograph of compostable container similar in design to the compostable container of figure 10A. Figure 12 is a photograph of the compostable container of figure 11 with the left handle and right handle rotated above the closure flap.

Figure IB is a photograph of the compostable container of figure 11 in a folded

configuration.

Figure 14 is a plan view drawing of a blank for the compostable container of figure 11.

Description of Embodiments:

The detailed description describes non-limiting exemplary embodiments. Any individual features may be combined with other features as required by different applications for at least the benefits described herein. As used herein, the term "about" means plus or minus 10% of a given value unless specifically indicated otherwise. As used herein, the term "substantially" means that an element has at least 90% of an indicated property.

A portion of the disclosure of this patent document contains material to which a claim for copyright is made. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but reserves all other copyright rights whatsoever.

As used herein, the term "shaped" means that an item has the overall appearance of a given shape even if there are minor variations from the pure form of said given shape.

As used herein, the term "generally" when referring to a shape means that an ordinary observer will perceive that an object has said shape even if there are minor variations from said shape.

As used herein, relative orientation terms, such as "up", "down", "top", "bottom", "left", "right", "vertical", "horizontal", "upper portion", "distal" and "proximal" are defined with respect to an initial presentation of an object and will continue to refer to the same portion of an object even if the object is subsequently presented with an alternative orientation, unless otherwise noted.

As used herein a "photograph" may include an original photograph that may have been edited to more clearly show elements originally present therein.

Disclosure of a given embodiment herein also is a disclosure of the mirror image embodiment, thereof. Disclosure of a left or right handed embodiment is also a disclosure of the opposite handed embodiment.

Examples

Figure 5 is a photograph of a compostable container 500 similar in design to the compostable container 200 of figure 2A. The compostable container 500 is made from kraft cardboard. The thickness of the cardboard is thick enough so that the container will remain erect (e.g. stand on its own). The thickness is thin enough so that the walls (e.g. left wall 508) will fold along crease lines (e.g. left wall crease 522). In this embodiment, a bottom crease 524 is provided in the satchel bottom 512 to allow the center of the bottom to fold up when the container is folded flat.

A holding tab 538 has been cut into the closure flap 514. The holding tab is positioned so that it can be reversibly engaged with an edge 530 of the opening 532 of the carrying handle 528.

A closure slot 518 has been cut into the front face 502 of the container at a position such that said closure slot can be reversibly engaged with a closure tab 516 proceeding down from the bottom edge of the closure flap. The closure flap is slightly open so that the container opening 510 can be seen.

Figure 6 is a photograph of the compostable container 500 with the closure flap 514 opened. A user has engaged the holding tab 538 with the edge 530 of the handle opening so that the closure flap is held away from the container opening 510. The interior surfaces of the container can be seen. The interior surfaces can be coated with a water-resistant coating 572. A water-resistant coating, however, may not be needed in applications where only dry material will be placed in the container.

Figure 7 is a photograph of the compostable container 500 in a folded configuration. The left wall 508 and right wall (not visible) have been folded in along their respective creases (e.g. item 522). Similarly, the satchel bottom 512 has been folded in along the bottom crease 524. When weight is placed on the front face 502, the compostable container will become substantially flat for packaging, shipping, and storage.

Compostable Container Blank Figure 8 is a plan view drawing of a blank 800 for making the compostable container 500. A surprising benefit of the design of compostable container 500 is that the compostable container can be made from a single blank. This simplifies manufacturing. The portions of the different elements of the container are shown. The entire blank is cut from a sheet stock and folded or creased along internally shown lines. The identified elements in the blank include a front left pleat 552, a side crease 522, a glue tab 542, a front face 502, a closure slot 518, a container opening 510 (material not yet removed), a bottom crease 524, a right side wall 506, additional glue tabs 542, a satchel bottom 512, a holding tab 538, a closure tab 516, a closure flap 514, a handle opening 532 (material not yet removed), a carrying handle 528, a back face 504, an additional glue tab 542, a left gusset 534, a left side wall 508 and a back left pleat 536. After the blank is cut, folded and creased, the glue tabs are glued to their respective front and back faces. The container may then be folded into a flat configuration, packaged, shipped, and stored by an end user.

Figure 9 is a plan view of a layout 900 of a plurality of the blanks 800 laid out on a board of sheet stock 902. A surprising advantage of the blank design 800 is that a plurality of blanks can be laid out in an efficient manner with minimum waste of the sheet stock. Further efficiencies may be gained by using optimization algorithms, such as genetic algorithms, to lay out the blanks for a given dimension of sheet stock.

Open Top Compostable Container

Figure 10B is a front left top perspective drawing of a compostable container 1000 with the container opening 1010 (not visible but indicated by broken lines) in the top. This design may be made from a single blank. The compostable container comprises a front face 1002, a back face 1004, a left wall 1008, a right wall 1006 and a satchel bottom 1012. The front face, back face, left wall and right wall each terminate in a horizontal top edge wherein all of said top edges are at about the same height. Said top edges collectively form said container opening 1010.

A closure flap 1014 is hingedly attached to the top edge of the back face. The closure flap is dimensioned to cover the container opening. A closure tab 1016 proceeds downward from a bottom edge of the closure flap. A closure slot 1018 is provided near the top of the front face. The closure tab is dimensioned to reversibly fit into the closure slot.

A holding tab 1038 is provided in the closure flap. A holding slot 1036 (not visible) is provided near the top of the back face. The holding tab and holding slot are dimensioned so that when the closure flap is folded rearward to uncover the container opening, the holding tab may be reversibly engaged with the holding slot to hold the closure flap against the back face. The holding tab can also be used for opening and closing purposes.

A left handle 1028 and a right handle 1026 may each be hingedly attached 1025, 1024 to the top edges of the left and right walls. Each handle may comprise a respective handle opening (e.g. 1032). Once the container is full, the closure flap may be rotated over the container opening and the closure tab may be engaged with the closure slot. The left and right handles may then be rotated upward and together to collectively form a carrying handle that is above the container opening. Thus, when the container is lifted, the closure flap is not pulled off of the container opening.

In an alternative embodiment, the left and right handles are attached to the upper edges of the front face and back face respectively. The closure flap may be hingedly joined to either the top edge of the left face or right face.

One or more creases (e.g. items 1022, 1023) may be provided in the handles, walls, satchel bottom and/or back face to allow the container to be folded into a flat

configuration.

Figure 10D is a left elevational drawing of the compostable container 1000. Figure IOC is a front elevational drawing of the compostable container 1000. Figure 10A is a plan view drawing of the compostable container 1000. The front face 1002 and the back face 1004 may be provided at a face angle 1042 greater than zero with respect to vertical. This will improve the front-to-back stability of the container. The left wall 1008 and right wall 1006 may be provided at a wall angle 1044 greater than zero with respect to vertical. This will improve the left-to-right stability of the container.

A suitable height 1066 of the container with the handles down is about 301 mm. A suitable top depth 1072 is about 121 mm. A suitable bottom depth 1062 is 150 mm. A suitable top width 1074 is about 119 mm. A suitable bottom width 1064 is about 150mm. These dimensions provide an internal volume 1001 of about 5 liters.

Alternatively, the container height may be about 301 mm, the top depth may be about 181 mm, the bottom depth may be about 210 mm, the top width may be about 179 mm, and the bottom width may be about 210 mm. These dimensions provide an internal volume of about 11 liters. Larger and small dimensions and different proportions may be provided for different applications.

The handle height 1060 may be selected so that the left and right handles can be held together when the handles are rotated above the container opening. The handle width 1058 may be selected so that there is no overlap between the handles and the closure flap when laid out as a blank.

Figure 11 is a photograph of a compostable container 1100 similar in design to the compostable container 1000. The left handle 1128 and right handle 1126 are hanging down. The closure flap 1114 is rotated over the container opening 1110, but the closure tab 1116 has not been engaged with the closure slot 1118 in the front face 1102. In this example, the closure tab comprises a side wing 1117 on each side of the distal end thereof. The side wings are dimensioned such that they will engage the closure slot and not be easily removable. Hence the closure tab will be fixedly engaged with the closure slot when the closure tab is inserted therethrough.

Figure 12 is a photograph of the compostable container 1100 with the left handle 1128 and right handle 1126 rotated above the closure flap 1114. The handles are rotated about their respective hinges 1125, 1124. The closure flap has been previously rotated over the container opening and the closure tab 1116 has been fixedly engaged with the closure slot 1118.

A right handle opening 1130 is aligned with the left handle opening 1132 such that the left and right handles collectively form a carrying handle 1138 located at about the longitudinal center of the closure flap. Thus, a user may pick up and carry the container with a single hand 1202 without requiring undue grip strength.

The handles may be removable or not present at all. They may also be attached by any means, such as glue magnet, and hook-and-loop fasteners. Figure IB is a photograph of the compostable container 1100 in a folded configuration. The closure flap 1114, satchel bottom 1112, left handle 1128 and associated handle crease 1123 are indicated.

Figure 14 is a plan view drawing of a blank 1400 for the compostable container 1100. The left handle 1128, closure flap 1114, right handle 1126, right handle hinge 1124, closure slot 1118, glue tab 1406, right wall 1106, bottom tab 1408, left wall 1108, crease 1122 and holding slot 1036 are indicated.

The left and right handles have a hinge width 1404 that is larger than an end width 1402. This prevents the handles from overlapping the closure flap when laid out on a blank.

Conclusion

While the disclosure has been described with reference to one or more different exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt to a particular situation without departing from the essential scope or teachings thereof. For example, this disclosure contemplates designs that are simple open top box structures that are collapsible to a flat form with optional separate covers provided. They may or may not have closure flaps. This disclosure also contemplates that the containers described herein may be made of non-compostable materials, such as plastics and metals. Hence any design disclosed herein may be termed as a "container". The containers described herein may be made from paper weight materials, such as that used for a paper shopping bag. The containers described herein may be the size of a standard paper shopping bag. The containers herein may be made from materials that are one or more of degradable, bio-degradable, recyclable, recycled or other eco-friendly materials. Recyclable materials include paper, such as kraft paper. Recycled materials, such as recycled paper, may include pre-consumer (e.g. trimming produced during manufacturing) and post consumer (e.g. newsprint). This disclosure also contemplates handles with opening on the one or more sides of the container. Said handles on the sides of the container may be integrated into the left or right walls of the container. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out the invention.

Claims

The Claims:

We claim:

1. A container comprising: a) a front face; b) a back face; c) a left wall; d) a right wall; e) a satchel bottom; f) a container opening on an upper portion of said container; and g) a carrying handle comprising a handle opening wherein: h) said left wall, said right wall and one or more of said back face and said satchel bottom comprise one or more creases such that said container can be collapsed to a folded configuration and opened to a set-up configuration comprising an internal volume for receiving one or more objects.

2. The container of claim 1 which further comprises: a) a closure flap adapted to cover said container opening and adapted to rotate away from said opening to allow said one or more objects to be put into said container. 3. The container of claim 2 wherein: a) said closure flap comprises a holding tab adapted to engage a holding

portion of said container such that said closure flap will be held away from said opening such that material can be passed through said opening.

4. The container of claim 3 wherein said holding portion of said container is one or more of an edge of said handle opening or a holding slot located on said back face.

5. The container of claim 1 wherein said container is made from a single blank of sheet stock. 6. The container of claim 1 wherein said container comprises interior surfaces and wherein said interior surfaces are coated with a compostable water-resistant coating.

7. The container of claim 6 wherein said water-resistant coating comprises one or more of polylactic acid, polybutylene adipate terephthalate or FlexSHIELD™ coating.

8. The container of claim 1 wherein: a) said front face forms a face angle with respect to vertical of more than zero degrees; b) said back face form a face angle with respect to vertical of more than zero degrees; c) said back face and said front face are joined at an apex; and d) said carrying handle proceeds vertically upward from said apex.

9. The container of claim 8 wherein: a) said container opening is on an upper portion of said front face; and b) said holding tab is adapted to reversibly engage said opening of said carrying handle.

10. The container of claim 1 which further comprises: a) a left handle hingedly joined to a top edge of said left wall; and b) a right handle hingedly joined to a top edge of said right wall wherein: c) said container opening is formed by: i) a top edge of said front face; ii) a top edge of said back face iii) said top edge of said left wall; and iv) said top edge of said right wall; d) said closure flap is hingedly joined to said top edge of said back face; and e) said left handle and said right handle are adapted to fold upwardly over said container opening and be held together to form said carrying handle.

11. The container of claim 10 wherein: a) said closure flap comprises a holding tab; and b) said back face comprises a holding slot wherein: c) said holding tab is adapted to reversibly engage with said holding slot to hold said closure flap away from said container opening. 12. The container of claim 1 wherein said container comprises a sheet of compostable material.

IB. The container of claim 12 wherein said sheet of compostable material comprises paper.

14. The container of claim 13 wherein said paper comprises kraft paper. 15. The container of claim 13 wherein said paper comprises recycled paper.

16. The container of claim 1 wherein said folded configuration is substantially flat.

17. The container of claim 1 wherein said handle opening is above said container

opening when said container is in said set-up configuration.

18. The container of claim 1 wherein said container comprises a sheet of degradable, bio-degradable, recyclable, or recycled material.

19. The container of claim 1 wherein said container comprises a sheet of cardboard.