Multi-aperture spill-resistant spout

Abstract

A spill-resistant spout and method of injection molding a spill-resistant spout. The spill-resistant spout includes a conduit portion having an exit aperture in fluid communication with a central channel; and a seal portion having a bottom surface, the seal portion secured to the conduit portion and in fluid communication with the central channel, the bottom surface comprising at least two intake apertures configured to receive foodstuffs from a container. The use of multiple intake apertures increases the surface tension on the foodstuffs attempting to pass through the intake apertures while maintaining or increasing the total flow volume of foodstuffs through the spill-resistant spout. Additionally, the barrier qualities of the spill-resistant spout can be enhanced by providing one or more discrete layers of thermoplastic material and one or more layers of barrier material within at least one portion of the spill-resistant spout.

What is claimed is: 
     
         1 . A method of injection molding a spill-resistant spout, the method comprising:
 injecting a thermoplastic resin into an injection port of a mold, the mold configured to form the spill-resistant spout with a conduit portion having an exit aperture in fluid communication with a central channel and a seal portion having a bottom surface, the seal portion secured to the conduit portion and in fluid communication with the central channel, the bottom surface comprising at least two intake apertures configured to receive foodstuffs from a container, wherein the injection port is proximate a center point of the bottom surface of the seal portion.   
     
     
         2 . The method of  claim 1 , wherein the at least two intake apertures comprise at least one of: four circular intake apertures or seven circular intake apertures. 
     
     
         3 . The method of  claim 1 , wherein the at least two intake apertures comprise two circular intake apertures. 
     
     
         4 . The method of  claim 1 , wherein the at least two intake apertures comprise two non-circular intake apertures, wherein each of the non-circular intake apertures are selected from at least one of: oval intake apertures, rectangular intake apertures, and star-shaped intake apertures. 
     
     
         5 . The method of  claim 1 , wherein the at least two intake apertures comprise two bean or kidney shaped intake apertures. 
     
     
         6 . The method of  claim 1 , wherein the at least two intake apertures are radially disposed about the center point of the bottom surface at equal radial intervals about the center point. 
     
     
         7 . The method of  claim 1 , wherein the injecting step includes injecting a first discrete layer of thermoplastic resin and a first discrete layer of barrier material. 
     
     
         8 . The method of  claim 7 , wherein the first discrete layer of thermoplastic resin is selected from at least one of: Acrylonitrile Butadiene Styrene (ABS), Acrylic, High Density Polyethylene (HDPE), Polypropylene, Polyethylene, Polystyrene, Polyvinyl Chloride (PVC), Polyethylene Terephthalate (PET), Polycarbonate, Polylactic Acid, Thermoplastic Starch, Polyhydroxyalkanoate, Polyhydroxybutyrate, Polybutylene succinate, Polyamide, cellulose fibers, cellulose nano crystals, or any combination thereof. 
     
     
         9 . The method of  claim 7 , wherein the first discrete layer of barrier material is selected from at least one of: Polyamide, Ethylene Vinyl Alcohol (EVOH), Polyvinyl Alcohol, Thermoplastic Starch, cellulose nano crystals, nano clay, or any combination thereof. 
     
     
         10 . The method of  claim 1 , wherein the at least two intake apertures are integrally formed in the bottom surface of the seal portion. 
     
     
         11 . The method of  claim 1 , wherein the seal portion is configured to permanently engage with the container. 
     
     
         12 . The method of  claim 11 , wherein one or more side surfaces of the seal portion are configured to permanently engage with the container. 
     
     
         13 . The method of  claim 1 , wherein the conduit portion and the seal portion are arranged concentrically about an axis A. 
     
     
         14 . The method of  claim 13 , wherein each of one or more side surfaces of the seal portion are substantially parallel to the axis A. 
     
     
         15 . The method of  claim 14 , wherein the one or more side surfaces comprise one or more lateral grooves configured to permanently engage with the container. 
     
     
         16 . The method of  claim 1 , wherein the mold includes one or more mold posts configured to form the at least two intake apertures. 
     
     
         17 . The method of  claim 1 , wherein the seal portion includes one or more wings. 
     
     
         18 . The method of  claim 1 , wherein the mold comprises a top half and a bottom half configured to matingly engage during the injecting step. 
     
     
         19 . The method of  claim 1 , wherein the at least two intake apertures comprise four intake apertures. 
     
     
         20 . The method of  claim 1 , wherein the at least two intake apertures comprise six intake apertures.