U.S. patent application number 09/921930 was filed with the patent office on 2002-01-03 for reclosable dispenser package, reclosable outlet forming structure and method and apparatus for making same.
Invention is credited to Redmond, Sanford.
Application Number | 20020000441 09/921930 |
Document ID | / |
Family ID | 26681194 |
Filed Date | 2002-01-03 |
United States Patent
Application |
20020000441 |
Kind Code |
A1 |
Redmond, Sanford |
January 3, 2002 |
Reclosable dispenser package, reclosable outlet forming structure
and method and apparatus for making same
Abstract
An aperture forming structure, which when attached to or
integrally formed in dispenser packages for flowable substances
allows reclosure and single or multiple uses. The aperture forming
structure includes a break away tip member of thermoformable
plastic. The break away tip includes a hollow protrusion from a
surface. The intersection of the hollow protrusion and the surface
is a fault line. Rupturing of the fault line creates an aperture
from which the contents of the dispenser package may exit. A cap
may be integrally formed with the aperture forming structure and
detached for protecting the hollow protrusion or for closing the
aperture created when the fault line is ruptured. The aperture
forming structure can be made by heating a relatively stiff
substantially flat thermoformable sheet of and then stretching the
sheet to create a first and a second hollow protrusion in a tiered
configuration. A rupture line is placed at the intersection of the
first and the second protrusions. The sheet may be attached to a
pouch or containment member formed from a flexible sheet which
contains any flowable substance.
Inventors: |
Redmond, Sanford; (Stamford,
CT) |
Correspondence
Address: |
MORGAN & FINNEGAN, L.L.P.
345 Park Avenue
New York
NY
10154
US
|
Family ID: |
26681194 |
Appl. No.: |
09/921930 |
Filed: |
August 6, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09921930 |
Aug 6, 2001 |
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09404008 |
Sep 23, 1999 |
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6299012 |
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09404008 |
Sep 23, 1999 |
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08788713 |
Jan 23, 1997 |
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6062413 |
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60010455 |
Jan 23, 1996 |
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Current U.S.
Class: |
220/266 ;
206/469; 206/484; 215/47; 215/48; 220/278; 220/375; 222/81;
229/125.15; 383/202 |
Current CPC
Class: |
B29C 2793/00 20130101;
B65D 5/746 20130101; B65D 75/5877 20130101; B29L 2031/565 20130101;
B29C 51/08 20130101 |
Class at
Publication: |
220/266 ;
220/278; 220/375; 215/47; 215/48; 206/469; 206/484; 222/81;
383/202; 229/125.15 |
International
Class: |
B65D 041/50; B65D
037/00 |
Claims
I claim:
1. An aperture forming means for packages or containers comprising
a break away tip member made of thermo-formed plastic comprising a
hollow protrusion from a surface whose entire intersection with
said surface comprises a locus of a fault line.
2. The aperture forming means of claim 1 wherein said hollow
protrusion is frusto-conical.
3. The aperture forming means of claim 1 wherein said surface
having said hollow protrusion site atop a covered cylindrical base
member formed and protruding from a thermo-formable plastic
film.
4. The aperture forming means of claim 1 wherein said hollow
protrusion is relatively shallow, said hollow protrusion having at
least one side indent.
5. The aperture forming means of claim 1 further comprising at
least one additional hollow protrusion adjacent said covering
cylindrical base member.
6. The aperture forming means of claim 5 wherein said at least one
additional hollow protrusion is a cap member for said hollow
protrusion.
7. The aperture forming means of claim 6 wherein said cap member
has an inward protrusion and said cylindrical base member has a
related cap member, such that when twisted, said cap member is
compressed into said cylindrical base member.
8. The aperture forming means of claim 6 wherein said cap member is
tapered.
9. The aperture forming means of claim 3 further comprising at
least one additional hollow protrusion so shaped as to function as
a cap member to fit snugly about said covered cylindrical base
member and over said hollow protrusion.
10. The aperture forming means of claim 5 wherein said at least one
additional hollow protrusion has an open end and a closed end, said
open end being a cap member and said closed end being a
punch/plug.
11. The aperture forming means of claim 5 wherein said one
additional hollow protrusion is so shaped as to function as a cap
member with a centrally formed punch/plug extending along a
longitudinal axis within said at least one additional hollow
protrusion.
12. The aperture forming means of claim 5 wherein said at least one
additional hollow protrusion is so shaped as to function as a tool
member atop of a cap.
13. The aperture forming means of claim 5 further comprising a
portion of a thin gauge material adjacent to and between said
protrusion and said at least one additional hollow protrusion so
cut as to form a tether therebetween.
14. An aperture forming means comprising a protrusion which is
cylindrical, said protrusion being formed from thermo-formable
plastic with one integral covered end, said covered end having a
fault line pattern which pattern, when pressed into a space defined
by said protrusion, ruptures in a predetermined pattern to create a
predetermined aperture.
15. The aperture forming means of claim 14 wherein said fault line
pattern creates a circular aperture.
16. The aperture forming means of claim 14 wherein said fault line
pattern creates a polygonal aperture.
17. The aperture forming means of claim 14 wherein said protrusion
is a hollow mound.
18. An aperture forming means comprising a thermo-formed member
having a hollow frusto-conical protrusion from a surface atop a
hollow cylindrical based member wherein an intersection of said
hollow frusto-conical protrusion with said surface atop said hollow
cylindrical based member comprises a locus of a fault line to
create a break away tip with an adjacent tethered cap member, said
break away tip and said tethered cap member being securely
sealingly attached to a container wherein said cylindrical based
member is located directly over a hole in said container.
19. Apparatus to form a hollow protrusion from heated thermoplastic
film where said hollow protrusion intersects said heated
thermoplastic film, said entire intersection comprising the locus
of a fault line, including: (a) punch means comprising a tip
portion with a shallow frusto-conical formation at the base of said
tip portion; and (b) a female die having an accurately bored hole
in a flat die block, said hole of slightly larger diameter than the
base of said tip portion of said punch means, so dimensioned that
when said punch means is introduced into said female die when
forming said heated thermoplastic film the base rim, if advanced to
contact said frusto-conical formation, the locus of such contact
would be a circle located approximately centrally between the
larger base circle and the smaller end circle of the frusto-conical
formation.
20. Apparatus to form a hollow protrusion from heated thermoplastic
film where said hollow protrusion intersects said heated
thermoplastic film, said entire intersection comprising the locus
of a fault line, including: (a) a supply of thermoplastic film; (b)
means to controllably heat a section of said film; (c) means to
transfer said heated film section to the locus of the center of
said apparatus; (d) punch means comprising a tip portion with a
shallow frusto-conical formation at the base of said tip portion
extending from a shaft; (e) resiliently mounted film clamp means
with a central hole through which said punch member may pass; (f)
guided mounting plate means to which said clamp means and punch
means are concentrically mounted with said punch means located
beneath the clamp face of said resilient clamp means and concentric
with its central hole to reciprocatingly and controllably advance
and retract said resiliently mounted film clamp means and punch
means with respect to a female die; and (g) a female die having an
accurately bored hole in a stationary flat die-plate located in
accurate alignment with said punch means, said bore diameter so
dimensioned that when the punch means is advanced said bore rim
would be in accurate alignment with said shallow frusto-conical
formation at the base of the punch tip and if advanced to contact
said shallow frusto-conical formation the locus of said contact
would be a circle located approximately centrally between the
larger base circle and the smaller end circle of said shallow
frusto-conical formation.
21. Apparatus to form a hollow protrusion from heated thermoplastic
film where said hollow protrusion intersects said heated
thermoplastic film, said entire intersection comprising the locus
of a fault line, which hollow protrusion extends from a closed
hollow essentially cylindrical base portion, including: (a) punch
means comprising a tip portion with a shallow frusto-conical
formation at the base of said tip portion; (b) a spring loaded
self-centering retractable female die member configured to mate
with said punch means, and (c) a spring loaded film clamp means
with a central hole through which said punch member may pass,
cylindrical means extending from said central hole whose outer
diameter functions as a punch means to form the inside diameter of
the closed hollow essentially cylindrical base portion and whose
height forms the inner height of said protrusion when cooperating
with said female die member.
22. The apparatus of claim 21 where the female die member includes
a ball ended base, wherein movement of said female die member is
limited in one direction by the ball ended base contacting an
adjustable stop means, a spring member seated on said adjustable
stop means compressor against a flange located on the female die
member pressing said flange against a fixed stop means to encapture
the female die member.
23. The apparatus of claim 21 including additional means to form an
adjacent cap member protrusion and tether from said heated section
of thermoplastic film, said additional means comprising: (a)
secondary punch means comprising a tip so shaped as to create a
hollow thermoplastic cap member with tapered walls to firmly engage
said hollow essentially cylindrical base portion when used in
conjunction with a cooperating female die member; (b) a female die
member comprising a hole in a plate of such dimension as to allow
punch member and heated thermoplastic film to pass through it with
low resistance; (c) said punch and die means located adjacent to
said apparatus to form said hollow cap member at such distance as
to permit a cutting means to create a tether between said cap means
and said hollow base portion; and (d) cutting means to create a
tether.
24. Apparatus to form a hollow tapered protrusion from heated
thermoplastic film where a fault line may be formed encircling an
outer surface of said protrusion at various predetermined heights
including: (a) punch means comprising a tapered tip extending from
a round shaft member; (b) a film stop plate with a hole so sized as
to permit said punch means and said heated thermoplastic film being
formed to pass through to reach a female die means; (c) female die
means comprising a bored die block, said bore to be of such
diameter as to locate the fault line on the outer surface of the
tapered member protrusion at a predetermined location when
cooperating with said punch member.
Description
[0001] This non-provisional application claims priority to U.S.
Provisional Application Ser. No. 60/010,455, filed Jan. 23, 1996,
and U.S. Provisional Application entitled "RECLOSABLE DISPENSER
PACKAGE, RECLOSABLE OUTLET FORMING STRUCTURE AND METHOD AND
APPARATUS FOR MAKING SAME", filed Jan. 3, 1997 by the same inventor
of the instant non-provisional application, both of which are
herein incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to easy opening, self-contained, easy
to use, single or multiple use dispenser packages capable of
economical, high speed production, manufactured from a broad range
of materials, many of which are recyclable. They may contain such
products as syrups, cream, cheeses, salad dressings, shampoo,
hand-cream, liquid detergents, motor oil, toothpaste pates, pet
food and many other products. It additionally relates to a package
which has the capability of dispensing the contained product, e.g.,
mouthwash, cough syrup, confections, alcoholic beverages, etc.,
directly into the mouth of the user, and which also includes a
reclosure cap member formed as an integral part of the package and
which preferably is tethered to the package by a tether also formed
integrally with the package. It will also be seen that the easy
opening feature together with the reclosure cap and tether may be
formed independently and sealed or adhered to the surface of many
packages such as bags, milk containers, pouches, pillow packages
(sachets), etc. to make for very efficient low cost dispensing
packages or squeeze bags. These squeeze bag type packages could
dispense food pastes such as pet food, cremes, grease, yogurt,
certain types of dough, cake frosting and could be made of
everything from treated, coated paperboard plastic films, foils,
laminates or coextrusions of these materials. The easy opening
means of this application in its preferred embodiment is comprised
of a drum-like protrusion from which a secondary frusto conical
protrusion extends to create a tip which is encircled at its base
by a fault line. To create the aperture this tip is broken away by
applying light lateral finger pressure. In order to protect this
breakaway tip during shipment or for reclosing the aperture, a
tethered cap is also formed adjacent to the double protrusion. The
tether functions not only to hold the cap, thereby preventing the
cap from being lost, but also to hold the cap [on the tip] in place
by acting like a spring.
[0003] In an alternate aperture forming system the initial drum
like protrusion has, instead of a frusto-conical breakaway tip, a
fault line pattern defined in its top surface, so designed as to
rupture to create an outlet of various required shapes when a
puncturing tool/plug is pressed into said fault line pattern. Such
puncturing tool/plug may be formed instead of a cap and may be
tethered or the cap may be double ended with a cap formation on one
end and the puncturing tool/plug formation on the other. It will
also be seen that a cap containing a protruding member formed
within the cap similar to the style of a flower would perform as a
central punch when the cap is pressed over the drum shaped
protrusion. It will further be seen that in certain instances where
a metal foil liner is required for a flowable product such as an
alcoholic drink the drum shaped protrusion may be replaced by a
moundlike protrusion with a central fault line pattern. The reason
for such a moundlike shape instead of the drum shape is to prevent
the stretching of the foil beyond its elastic limit at surface
intersections in which case it would rupture during formation. Said
pattern able to be punched open by a formed puncturing tool/plug
said puncturing tool/plug may be thermoformed and tethered to the
unit or may be independently made and the tether may have a formed
ring at its free end into which the puncturing tool plug may be
seated.
[0004] This invention also relates to a method and apparatus for
manufacturing the aforesaid formation and packaging, reliably at
high speed, in many cases from fully recyclable material, so as to
permit such packages to be produced at low cost and, in many cases,
recyclable. Additionally the packages may use less plastic material
than most other previously known portion packages leading to source
reduction and environmental benefits even when non-recyclable
materials are used.
BACKGROUND OF THE INVENTION
[0005] Various attempts have been made to provide a dispenser
package in which a product may be packaged in the quantity normally
required for single or multiple uses, and from which the contained
product may be dispensed.
[0006] One type of such dispenser packages is a pillow pouch or
sachet, typically made of relatively thin plastics and foils or
combinations of laminated plastics and foils. These packages are
most frequently encountered as containers for catsup, mustard,
other condiments, homecare preparations such as hair conditioners,
dyes and cremes, etc. Although this type of package is universally
used, it is also universally disliked by the consumer. In order to
access the contents, the pouch must be held in one hand while a
tearing motion and force are applied by the other hand. Creating
the initial tear to break the packages seal is often very
difficult, often requiring the assistance of the user's teeth.
Moreover, once the initial tear is created, the laminated foil
and/or plastic material not only often tears in an uncontrolled
fashion, but the holding pressure exerted by one of the user's
hands often forces the contents out of the envelope not only before
the user is ready to apply the contents, but even before the
tearing motion is complete. Opening these packages leads to frayed
tempers, broken fingernails, and chipped teeth, as well as other
problems. The user must also use both hands to open the container.
In the case of invalids, arthritis sufferers and other handicapped
people, opening these packages is virtually impossible. Yet another
problem associated with these prior packages is the impossibility
of efficient reclosure, thereby precluding multiple use of the
package, with consequent waste of the unused contents. Further
disadvantages include the sachet's inability to function
effectively with low viscosity products such as coffee cream,
mouthwash or alcoholic beverages, due to the inability of the torn
opening to control the direction of flow of such liquids from the
package. These packages also are generally totally unrecyclable,
and therefore become environmental pollutants. As above-mentioned
however, should continued use of these sachets be preferred, then
the easy opening feature of this application may be readily and
economically adhered to the sachet to make for an easy opening,
reclosable, high-barrier package.
[0007] Another dispenser package is the peel-top cup used for
butter, margarine, syrup, sauces, salad dressing, and other similar
products. This type of package requires good eyesight and manual
dexterity. Such packages are often used as coffee creamers and have
many disadvantages, including difficulty in peeling off the top in
order to open, as well as difficulty in pouring, accidental
spilling, and the inability to be reclosed so as to preclude more
than a single use. Again the inventions described herein can be
adhered or integrally formed into these packages to make them easy
opening and reclosable. Yet another type of dispenser package is
the unsealed corrugated paper package used for salt and/or pepper,
which upon bending along an interrupted line cut through the
corrugations forms an opening through which the salt or other
material contained in the package may flow. These packages only
dispense dry, solid flowables with the assistance of gravity, and
cannot be used to contain, no less dispense, "wet" or liquid
flowable materials. The package of this invention can contain and
readily dispense both liquids and dry granular products.
[0008] Small, very expensive, metal capped bottles are used for
alcoholic drinks and are either poured or consumed directly from
the bottle. These bottles may be reclosed, but often are sized for
a single drink so they do not have to be reclosed. The instant
package can be used for alcoholic beverages at a fraction of the
cost of the bottles.
[0009] Everyone is familiar with the ubiquitous gable top milk
carton and everyone is familiar with the varying degrees of
difficulty in opening them. These range from fingernail breaking to
just plain unopenable without a knife or other tool.
[0010] They never truly reclose and at best are messy and unclean
looking. In the U.S. there has been a move toward mounting a
screw-on cap combination comprising a threaded nozzle member which
is sealed onto one of the slanted gables of the carton and the
other is an unattached screw-on cap. This little injection molded
duo is costly to make and to install, possibly on the order of 3 to
5 cents and is commonly used on large gable top juice containers in
the half gallon size. These are expensive, high profit items
selling for about three dollars each and can bear the extra tariff
for the screw-on outlets. There are however billions of these gable
top units sold annually for milk and cream in varying sizes from
half-pints to half gallons. Producers however are reluctant to
increase carton cost significantly and the public continues to use
difficult to open cartons.
[0011] The instant invention makes available a sealed and tamper
evident outlet with a tethered cap, both formed in a single, small
plastic unit which can be readily sealed or adhesively attached to
the gable over a small pre-made hole. It is ultra low cost and may
be made of polypropylene, high density polyethylene, PVC. Polyester
etc. utilizing material costing small fractions of a cent. It will
be seen that the cap serves a double purpose. It enables the outlet
to be reclosed after opening and of equal importance, since the cap
is in place over the breakaway tip during shipment it protects the
tip from being accidentally hit or subjected to any forces which
may open the outlet.
[0012] It may be seen that the lower drum-like formation beneath
the breakaway tip may be elongated so that when the tip is broken
away, an elongated nozzle remains which would allow the flowable
substance to be ingested directly from the container or as in the
case of motor oil, being poured directly into the engine oil inlet.
Another disadvantage currently experienced with dispensing packages
is the closing of the outlet opening. Closing the outlet opening of
tubes is presently accomplished by means of an injection molded
screw-on cap which normally includes a compressible gasketing
material. The end of the tube requires a mating thread to match the
cap. Both the separately molded gasketed cap and the threaded tube
result in increased manufacturing costs. Additionally, the cap, as
often as not, is dropped and/or lost while it is being threaded on
or off. Furthermore, there has been a growing trend to manufacture
such tubes at still greater cost by providing hinged caps with a
flat end surface which permits the tube to stand upright. Thus, the
cap members currently in use have the disadvantage that they tend
to increase the overall cost of manufacture of the dispensing
package.
OBJECTS OF THE INVENTION
[0013] It is therefore an object of this invention to provide a new
and improved means of creating an aperture in a thermoformable
plastic material as well as an integrally formed cap and tether
where necessary.
[0014] A further object is to form independently such aperture
creating means with or without a cap and/or tether for adhesion to
other forms of previously difficult to open or non-reclosable
packaging.
[0015] Another object of this invention is to provide new and
improved dispenser packages.
[0016] Another object of this invention is to provide a new and
improved aperture-forming structure for a dispenser package which
allows the user to easily and controllably dispense the contents of
the package directly to the user's mouth or in a directionally
controlled manner, as desired.
[0017] Another object of this invention is to provide a new and
improved aperture-forming structure for a dispenser package which
opens easily and reliably and yet which can be manufactured
economically and at high speed.
[0018] Another object of this invention is to provide a new and
improved reclosable dispenser package so that the contents thereof
may be dispensed in consecutive uses and the outlet opening
reclosed between uses.
[0019] A further object of this invention is to provide a new and
improved reclosable package with an attached cap member formed from
the same plastic film which cap member may be thereafter placed
over the unopened aperture forming means to protect it and/or to
reclose the package after opening.
[0020] Another object of this invention is to provide a new and
improved reclosable package and removable cap member which may be
formed as an integral unit and where the cap member is attached to
an integrally made tether and remains attached to the package and
which may be placed over the unopened aperture forming means to
protect it from changes or accidental opening during shipping and
handling.
[0021] Another object of this invention is to provide a new and
improved reclosable package and tethered cap member which may be
formed as an integral unit from a thermoformable material.
[0022] Another object of this invention is to provide a new and
improved reclosable package and tethered cap member which may be
formed as an integral unit from a thermoformable plastic material
that is recyclable.
[0023] Another object of this invention is to provide a new and
improved dispenser package and cap member wherein the cap member
has an open-ended top of predetermined shape so that, upon placing
the cap over the aperture of the package the contents may be
dispensed in such shaped stream.
[0024] Another object of this invention is to provide a new and
improved dispenser package and cap member wherein the cap member
includes a utensil device such as tiny protrusions or a flattened
surface structure so that the cap member may function as a tool to
brush, spread, or otherwise handle the contents dispensed from the
package.
[0025] Another object of the invention is to replace the cap member
with a dual function punch/plug member capable of punching through
a tough pre-scored formation to create an aperture and to further
act as a plug to close said aperture.
[0026] A still further object of this invention is to provide a new
and improved method of making a dispenser package embodying the
aforesaid features.
[0027] Another object of this invention is to provide a new and
improved method of thermoforming a dispenser package from a
recyclable plastic material at high speed and yet provide a
finished package which may be easily and reliably opened by the
user.
[0028] Another object of this invention is to provide a new and
improved apparatus for forming an aperture-forming structure for a
dispenser package.
[0029] Another object of this invention is to provide a new and
improved apparatus for forming a nozzle-like aperture structure in
a dispenser package so that, upon opening, the contents of the
package may be dispensed in a directionally controllable
manner.
[0030] Another object of this invention is to provide a new and
improved self-centering and self-aligning punch and die apparatus
adapted to accurately and reliably form a thermoformable material
into a hollow tip-like configuration having a peripherally
extending fault line so as to permit the tip to be readily broken
away by the user to form an aperture opening through which the
contents of the package may be dispensed.
[0031] The foregoing specific objects and advantages of the
invention are illustrative of those which can be achieved by the
present invention and are not intended to be exhaustive or limiting
of the possible advantages which may be realized. Thus, these and
other objects and advantages of the invention will be apparent from
the description herein or can be learned from practicing the
invention, both as embodied herein or as modified in view of any
variations which may be apparent to these of ordinary skill in the
art, the same being realized and attained by means of the parts,
constructions and instrumentations, and combinations thereof, as
well as in the steps and processes pointed out in the appended
claims. The present invention resides in the novel parts,
constructions, arrangements, combinations, steps and processes, and
improvements, herein shown and described.
SUMMARY OF THE INVENTION
[0032] Briefly described this invention is directed to a new
reclosable aperture forming means which may be formed with an
integrally formed cap member which may be tethered to said aperture
forming means to create a unit which may be independently formed
and adhesively or sealingly attached to a container wall or surface
over a hole in said container wall to create an easy opening,
reclosable, when necessary, dispensing package. Said reclosable
aperture forming means embodying an integral, hollow protrusion
member preferably comprised of two stages, a drum shaped base from
which extends a generally conical or frusto-conical tip, said tip
member having a fault line encircling it at its juncture with the
flat top surface of the first drumlike formation which may be
readily broken off to form an opening through which the contents of
the package may be dispensed in a directionally controllable
stream. After the tip of the protrusion member is broken off by
applying light lateral finger pressure, the desired quantity of the
contents may thereafter be expelled through the opened nozzle-like
outlet by gentle hand squeezing of the package.
[0033] In a second embodiment the entire reclosable aperture
forming means may be integrally formed into what will become an
easy to use reclosable dispensing package. In this second
embodiment a generally relatively flexible, compressible pouch or
container member is sealably attached to a cover member forming the
top or lid of the package. The cover member includes the new
reclosable aperture forming means and tethered cap member as
described above and similarly used.
[0034] In another desirable embodiment the pouch or container
member has the integral hollow protrusion and tethered cap member
thermoformed into the underside of its relatively stiff rim. The
advantage of this version being that the cover member then becomes
a relatively thin skinlike member which is very easy to print and
less expensive than the formed upper cover member.
[0035] The aforesaid cap member which is initially formed with the
package as an integral unit is preferably formed along one
peripheral edge of either the cover member forming the top or lid
of the package relatively closely adjacent to the breakaway
protrusion member or on the underside of the rim. A cut line may
create a tether member which permits the cap member to be
mechanically removed by the user from its molded position in
production and placed over the opened nozzle-like aperture forming
means so as to protect the breakaway tip during shipping and
handling, while remaining tethered to the package. As also
preferably embodied, the aforesaid cap member permits the end user
of the package to readily open or reclose the package after each
use.
[0036] In other alternative embodiments of the dispenser package of
the present invention:
[0037] (i) the breakaway protrusion member forming the aperture in
the package may be broken off at the surface of the cover member
forming the top or lid of the package, thereby eliminating the
nozzle-like outlet configuration in those applications where the
contents of the package don't require nozzle formation;
[0038] (ii) the cap member may be formed with miniature protrusions
to act like a brush, or may have some other desired shape to
perform some other desired tool function for use in handling the
contents dispensed from the package, such as by brushing or
spreading;
[0039] (iii) if reclosing the package is not required, the cap
member may be open-ended having a predetermined shape such that,
upon placing the cap member over the nozzle-like aperture of the
package, the contents may be dispensed in such shaped stream;
[0040] (iv) the cap member may be provided with an internal central
plug dimensioned to mate with the opening formed in the dispenser
package to thereby serve as a plug to further ensure sealing of the
opening after removal of the breakaway protrusion member; and
[0041] (v) the breakaway protrusion and tethered cap members may be
formed in a portion of the cover member which extends beyond one
end of the compressible pouch member at a predetermined angle and
communicates with the product contained in the pouch by means of a
shallow neck or channel, thereby facilitating application of the
contents of the package onto a surface, such as, e.g., toothpaste
onto a toothbrush or glue onto a break line. Alternatively, the
breakaway protrusion member may be formed in the cover member
directly over the pouch portion with the cap formed at an adjacent
small flat area. This method yields a somewhat larger pouch volume
while using the same total amount of material.
[0042] It will be understood that the foregoing preferred
embodiments of the dispenser package of the present invention may
be thermoformed from a wide variety of plastic materials,
including, e.g., PP (polypropylene) Barex, HDPE (high density
polyethylene), HIPS (high impact polystyrene) and foamed HIPS, as
well as various laminations and/or coextrusions of the aforesaid
materials and other plastic materials, including, e.g., PP/EVOH
(ethylene vinyl alcohol)/PP; Barex/PP; Barex/EVOH/PP; PET
(polyethylene tetrafluoride)/LLDPE (linear low density
polyethylene); PET/EVOH/LLDPE; PVC (polyvinylchloride)/LLDPE; NY
(nylon)/LLDPE; and NY/EVOH/LLDPE. Alternatively, the aperture
forming means and the dispenser packages of the present invention
may be formed by injection molding.
[0043] It also will be understood that the foregoing preferred
embodiments of the dispenser packages of the present invention may
be manufactured in a wide variety of sizes, as desired, although
the preferred size range is from about 2 ml capacity to about 4
fluid ounce capacity. Similarly, the aforesaid package may be
manufactured in a wide range of dimensions. A typical size for a
package containing 30 ml or 1 fluid ounce of material is on the
order of about 1 inch deep by about 1 inch wide by about 3 to 4
inches long, which fits comfortably in the palm of the hand of most
users. Furthermore, the independent formations of aperture forming
means and the tethered caps may be applied to a very wide range of
packaged from single use sizes to half gallons.
[0044] Briefly described, as preferably embodied, the apparatus of
the present invention forming the preferred aperture-forming
protrusion member in the cover member of the dispenser package
includes a two-stage punch member which advances to engage and
clamp a thermoformable material against a self-centering and
self-aligning hollow anvil member. The first punch member advances
to initially form a hollow, drum-shaped protrusion in a specific
heated area of the thermoformable material. Thereafter, a second
punch member preferably located within, and moveable relative to,
the first punch member continues to advance forward. The second
punch member includes a first generally frusto-conically shaped
surface adapted to form a substantially cylindrical or
frusto-conically shaped hollow tip member extending from the
drum-like protrusion formed by the first punch member. At the
moment formation of the hollow tip member is completed, the forward
advancement of the second punch brings a second shallow conical
surface into cooperating engagement with the peripheral edge or rim
defining the hollow portion of the anvil member to thereby compress
the wall of the formed hollow tip about a peripheral portion
thereof to create a weakened fault line in the hollow tip
protrusion member. As here preferably embodied, the aforesaid punch
and anvil members create a fault line at the base of the aforesaid
hollow tip protrusion member which extends continuously about the
periphery thereof.
[0045] In an alternative embodiment of the apparatus of the present
invention, the heated sheet of thermoformable material is clamped
against the anvil member and a single stage punch member having a
generally frusto-conically shaped forward end portion is thereafter
advanced to form the aforesaid hollow, substantially cylindrical or
frusto-conically shaped tip member. At the moment formation of the
hollow tip member is completed, the rim of the anvil member
compresses the wall of the hollow tip member about the periphery
thereof to create a weakened fault line. It will be seen that the
heated thermoformable film (material) may be clamped against a
relatively thin plate spaced away from the anvil which contains an
accurately aligned hole centered on the aperture of the anvil
member. In this embodiment, between the punch and anvil the film
will be formed into a conical member as the punch is advanced
through the plate and said conical member will then be further
formed until it contacts the peripheral edge or rim at the opening
of the aperture in the anvil. This alternate apparatus creates a
fault line banding or girdling the formed conically-shaped tip
member at a predetermined point between its base and its apex.
[0046] It will be appreciated by those skilled in the art that the
foregoing various brief descriptions and the following detailed
description are exemplary and explanatory of the present invention,
but are not intended to be restrictive thereof or limiting of the
advantages which can be achieved by the invention or various
combinations thereof. The accompanying drawings, referred to herein
and constituting in part hereof, illustrate preferred embodiments
of the invention and, together with the detailed description, serve
to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a side elevation view of a dispenser package
constructed in accordance with the present invention with an
integrally formed cap member;
[0048] FIG. 2 is a top plan view of the dispenser package of FIG.
1;
[0049] FIG. 2a is a perspective view of a dispenser package
constructed in accordance with the present invention with an
integrally formed cap member on the underside of the containment
members rim and their skin like unformed cover member;
[0050] FIG. 3 is an end view of the dispenser package of FIG.
1;
[0051] FIG. 3a is an end view of the dispenser package of FIG. 2a
showing an unformed very thin flexible cover member;
[0052] FIG. 4 is a side view in elevation, partly sectional, of an
apparatus constructed in accordance with the present invention for
forming the breakaway tip and nozzle protrusion members in a heated
sheet of thermoplastic material;
[0053] FIG. 5 is an enlarged sectional view, partly in elevation,
of the first and second punch members and the self-aligning hollow
anvil member illustrated in FIG. 4, this view illustrating
formation of the first protrusion member in the thermoplastic sheet
material;
[0054] FIG. 6 is an enlarged view similar to FIG. 5, illustrating
formation of the second protrusion member in the thermoplastic
sheet material;
[0055] FIG. 7 is an enlarged view of FIG. 6, illustrating formation
of the peripherally extending weakened fault line at the base of
the second protrusion member;
[0056] FIG. 7a an enlarged side plan view of first and second
protrusion members according to one embodiment of the present
invention;
[0057] FIG. 7b is an enlarged side plan view of first and second
protrusion members according to one embodiment of the present
invention;
[0058] FIG. 8 is an isometric view of the dispensing package of
FIG. 1;
[0059] FIG. 9 is an enlarged isometric view of the dispensing
package of FIG. 8, illustrating the cap member removed from its
molded position and placed over the breakaway tip protrusion
member;
[0060] FIG. 10 is a schematic illustration showing the use of a
hollow punch member for forming a central sealing plug member in
the cap member illustrated in the preceding drawings;
[0061] FIG. 11 is an isometric view of a cap member formed with a
central plug from the apparatus of FIG. 10;
[0062] FIG. 12 is an enlarged cross-sectional view, partly in
elevation, illustrating an alternative embodiment of the punch and
anvil apparatus of the present invention, wherein a single punch
member forms a hollow frusto-conical protrusion in the surface of
the cover member for a dispenser package and the anvil member
compresses the wall of the tip to form a peripherally extending
fault line on the surface of the protruding tip;
[0063] FIG. 12a is an enlarged cross-sectional view, partly in
elevation, illustrating an alternative embodiment of the punch and
anvil apparatus of the present invention, wherein a single punch
member forms a hollow frusto-conical protrusion having a
right-cylindrical base in the surface of the cover member for a
dispenser package and the anvil member compresses the wall of the
tip to form a peripherally extending fault line on the surface of
the protruding tip;
[0064] FIG. 12b is an enlarged cross-sectional view, partly in
elevation, illustrating an alternative embodiment of the punch and
anvil apparatus of the present invention, wherein a single punch
member having a spherical tip forms a hollow mound protrusion in
the surface of the cover member for a dispenser package and the
anvil member compresses the wall of the tip to form a peripherally
extending fault line on the surface of the mound;
[0065] FIG. 13 is a schematic elevation view of the breakaway tip
formed by the punch and anvil members illustrated in FIG. 12;
[0066] FIG. 13a is a schematic elevation view of the breakaway tip
formed by the punch and anvil members illustrated in FIG. 12a;
[0067] FIG. 14 is a top plan view of another embodiment of a
dispenser package constructed in accordance with the present
invention, wherein the breakaway tip and cap member are formed in a
lateral extension of the cover member and the breakaway tip member
communicates with the containment pouch through a shallow channel
member;
[0068] FIG. 15 is a side view of the embodiment illustrated in FIG.
14;
[0069] FIG. 16 is an end view of the embodiment illustrated in FIG.
14;
[0070] FIG. 17 is a side view of the embodiment of the invention
illustrated in FIG. 14, wherein the lateral extension of the cover
member also extends angularly downwardly;
[0071] FIG. 18 is a schematic view of an alternate embodiment of
the cap member, formed with bristles or nubs on its outer
surface;
[0072] FIG. 19 is a schematic view of another alternate embodiment
of the cap member, formed with a flattened spreader tool utensil on
its outer surface;
[0073] FIGS. 20a-d are partial end views of still other alternate
embodiments of the cap member of the present invention, each view
illustrating an open-ended cap member;
[0074] FIG. 21a is a top plan view of a reclosable outlet aperture
forming structure which can be applied to various forms of
containers in accordance with an alternate embodiment of the
present invention;
[0075] FIG. 21b is a side view of the reclosable outlet aperture
forming structure shown in FIG. 21a;
[0076] FIG. 22a is a perspective view of the reclosable outlet
aperture forming structure of FIGS. 21a-b, as applied to a milk
carton, in which the cap is placed over the outlet;
[0077] FIG. 22b is a perspective view of the reclosable outlet
aperture forming structure of FIGS. 21a-b, as applied to a milk
carton, in which the cap is removed from the outlet so as to allow
removal of the breakaway outlet tip;
[0078] FIG. 22c is a perspective view of the reclosable outlet
aperture forming structure of FIGS. 21a-b, as applied to a milk
carton, in which the breakaway tip is removed from the outlet to
form an opening therethrough;
[0079] FIG. 22d is a perspective view of the milk carton of FIGS.
22a-c, in which the breakaway tip is removed from the outlet to
form an opening through which milk is being poured;
[0080] FIG. 23 is a side view of a low profile breakaway tip in
accordance with another embodiment of the present invention;
[0081] FIG. 23a is a side view of a low profile breakaway tip in
accordance with another embodiment of the present invention;
[0082] FIG. 24 is a top view of the low profile breakaway tip of
FIG. 23;
[0083] FIG. 24a is a top view of the low profile breakaway tip of
FIG. 23a;
[0084] FIG. 25 is a perspective view of the low profile breakaway
tip of FIG. 23 with the removed breakaway tip shown in phantom;
[0085] FIG. 26 is a side view of a cap for use with the low profile
breakaway tip of FIG. 23;
[0086] FIG. 27 is a side view of a another embodiment of the
present invention which utilizes a twist-lock or twist-threading
arrangement to secure the cap to the base formation;
[0087] FIG. 28a is a perspective view of another embodiment of the
present invention in which a tethered plug is used to open and
close a pre-scored surface;
[0088] FIG. 28b is a perspective view of the embodiment of FIG. 29a
in which the pre-scored surface has been opened;
[0089] FIG. 28c is a perspective view of the embodiment of FIG. 28a
in which the plug has been placed in the outlet hole, thereby
opening the hole along the pre-scored surface and/or plugging the
hole;
[0090] FIGS. 29a-d are top views of the outlet of the embodiment of
FIG. 28a depicting various types of scored surfaces formed in the
outlet; and
[0091] FIGS. 30a-d are side views of the scored surfaces shown in
FIGS. 29a-d, in which each of the scored surfaces haves been
penetrated to create an opening therethrough and a flap descending
from the surface;
[0092] FIG. 31 is a partially elevated side view of an outlet
forming structure according to an alternative embodiment of the
present invention, having a punch/plug and a scored mount, as
applied to a milk carton;
[0093] FIG. 32 is a top plan view of the outlet forming structure
of FIG. 31;
[0094] FIG. 33 is a side plan view of the outlet forming structure
of FIGS. 31 and 32;
[0095] FIG. 34 is an enlarged elevated view of the outlet forming
structure of FIGS. 31-33;
[0096] FIG. 35 is an enlarged side plan view of the outlet forming
structure of FIGS. 31-34 showing the mound as punctured by the
punch/plug;
[0097] FIG. 36 is an enlarged side plan view of the mound of FIGS.
31-35;
[0098] FIG. 37 is a side plan view of an alternative embodiment of
the present invention in which an outlet forming structure, having
a breakaway tip and cap, is applied to a foil package;
[0099] FIG. 38 is an enlarged side elevational view of the outlet
forming structure of FIG. 37;
[0100] FIG. 39 is an elevated plan view of an alternative
embodiment of the present invention as applied to a foil
package;
[0101] FIG. 37a is a side plan view of an alternative embodiment of
the present invention in which an outlet forming structure is
applied to a foil package;
[0102] FIG. 38a is a front plan view of the outlet forming
structure of FIG. 37a;
[0103] FIG. 39a is an elevated plan view of the outlet forming
structure of FIGS. 37a and 38a;
[0104] FIG. 40 is a partial elevational view of an outlet forming
structure according to another alternative embodiment of the
present invention, having a snap-in auxiliary punch/plug/cap and
protrusion member, that is manufactured by a pick-and-place
method;
[0105] FIG. 40a is an enlarged side plan view of the outlet forming
structure of FIG. 40 showing the punch/plug/cap puncturing the
protrusion member;
[0106] FIG. 41 is a top plan view of an alternative embodiment,
wherein the outlet forming structures are formed from a single
thermoplastic web in a mating arrangement;
[0107] FIG. 42 is a side plan view of an alternative embodiment of
the present invention in which the reclosable container is provided
with a scored protrusion and a dual purpose tethered punch/cap;
[0108] FIG. 43 is a top plan view of the reclosable container of
FIG. 42;
[0109] FIG. 44 is a top plan view of the reclosable container of
FIGS. 42 and 43, wherein the tethered punch/cap is securely
fastened over the scored protrusion;
[0110] FIG. 45 is an elevated plan view of an outlet forming
structure according to one embodiment of the present invention;
[0111] FIGS. 46a-c are side plan views of a container for use with
an outlet forming structure according to the present invention;
[0112] FIG. 47 is an elevated plan view of the container of FIGS.
46a-c with the outlet forming structure of FIG. 45 mounted
thereon;
[0113] FIG. 48 is a top plan view of a container according to an
embodiment of the present invention;
[0114] FIG. 49 is a side plan view of the container of FIG. 49;
[0115] FIG. 50 is a side plan view of the container of FIGS. 48 and
49 in a closed position;
[0116] FIG. 51 is a side perspective view of the container of FIGS.
48-50;
[0117] FIG. 52 is a side elevational view of a container according
to an embodiment of the present invention;
[0118] FIG. 53 is an enlarged side plan view of the outlet forming
structure of FIG. 52; and
[0119] FIG. 54 is a top plan view of a section of a web of
thermoformable material having a series of outlet forming
structures formed therein.
DETAILED DESCRIPTION OF VARIOUS PREFERRED EMBODIMENTS
[0120] Referring now more particularly to FIGS. 1-4 and 9 of the
accompanying drawings, there is illustrated a dispensing package
indicated generally at 10 according to the present invention. The
package 10 can be used for single or multiple uses and can be
reclosed for further use.
[0121] As illustrated in FIGS. 1 and 4, the package 10 includes a
cover member 11 formed from a flexible but relatively stiff
generally flat sheet 12 of a thermoformable plastic material most
suitable to the product contained and the protection that the
contained product requires.
[0122] Materials such as high-impact polystyrene (HIPS), high
density polyethylene (HDPE) polyester, HDPE/EVOH (high density
polyethylene/ethylene vinyl alcohol), Barex, polypropylene, etc.
may be used. HIPS, HDPE, and HPDE/EVOH are each low cost and can be
recycled. HDPE/EVOH creates a superior O.sub.2 barrier.
[0123] As will be understood by those skilled in the art, whereas
plastics of similar material may be heat-sealed or bonded together,
heat sealing different plastics together requires an adhesive
layer. Preferably, linear low density polyethylene (LLDPE) is used
as such a layer. Thus, multi-layered plastics formed by coextrusion
may be sealed together to form sheet 12 having sealant/barrier 14
of the present invention.
[0124] Also suitably bonded to one face of bonded sheet 12, 14 is a
flexible sheet 18 forming at least one pouch chamber 22 adjacent
one face of the relatively stiff sheet 12 or bonded sheet 12, 14
for containing a preferably flowable substance, e.g. a dry powdered
or granulated material or a liquid material of any suitable
viscosity capable of flowing under light to moderate hand
pressure.
[0125] Advantageously, and as here preferably embodied, the layer
of a suitable sealant/vapor impervious barrier material 14 is
suitably integrally bonded to sheet 12 on the inner surface 16
which faces flexible sheet 18. Flexible sheet 18, advantageously
formed by conventional means, such as vacuum forming, pressure
forming, mechanical forming or combinations thereof, is likewise
suitably integrally bonded to either inner surface 16 or
sealant/barrier 14 of sheet 12, as the case may be.
[0126] The bonds between substantially flat relatively stiff sheet
12, sealant/barrier material 14 and flexible sheet 18 also may be
formed by conventional means known to persons of ordinary skill in
the packaging art, such as welding, heat sealing, or adhesive or
cohesive bonding. It will be understood that the particular bonding
method selected depends upon the particular properties of the
materials used and the flowable substance(s) to be contained in the
package.
[0127] Advantageously, and as preferably embodied, sheet 12 is
preferably made of polypropylene (PP), Barex, high impact
polystyrene (HIPS) or high-density polyethylene (HDPE), but when
combined with barrier 14 may be made of polystyrene, polyester,
EVOH (ethylene vinyl alcohol), polyvinyl chloride (PVC),
polyethylene tetrafluoride (PET) or nylon, or a copolymer thereof,
and barrier 14 is made of a suitable sealant/vapor impervious
barrier material, preferably comprising saran and foil laminate, or
comprising a laminate of foil and vinyl, or foil alone, depending
on the nature of the contents to be contained.
[0128] A particularly tough high barrier construction comprises
saran laminated on each side with polyethylene (sold by Dow
Chemical Co. under the name "Saranex") as barrier sheet 14, in turn
laminated onto polystyrene or polyester, forming the flexible but
relatively stiff sheet 12. The thickness of sheet 12 varies
according to factors, such as the properties of the materials used,
the flowable substance contained, and the intended usage. A
generally utilized range is 4-12 mils (0.004-0.012"). As previously
noted, sheet 12 preferably is somewhat flexible, although more
rigid than the material 18 forming pouch 22, and preferably is
stiffened by raised portion 11a formed in cover 11 in the preferred
construction of package 10.
[0129] It will be understood by those of ordinary skill in the art
that the bonds formed between materials 12, 14 and 18 can be
obtained by the conventional means previously described, again
depending on the nature of the flowable substance being
contained.
[0130] It will be seen from the foregoing that the structure of
FIGS. 1 and 2 forms an enclosed pouch or chamber 22 between the
flexible sheet 18 and the relatively stiff member 12, 14 in which a
preferably flowable substance is contained and from which the
contained substance is dispensed.
[0131] In accordance with the present invention as preferably
embodied, the relatively stiff generally flat sheet 12 forming
cover 11 includes an aperture-forming protrusion structure 30 which
includes a neck member 32 and a breakaway tip member 34 so that,
upon removal of tip 34, neck 32 forms a nozzle-like aperture in
package 10 through which the contents may be dispensed in a
directionally controllable manner.
[0132] Neck and tip protrusions 32, 34 preferably are substantially
hollow, substantially cylindrical and tip 34 preferably is
substantially cylindrical or frusto-conical. In the preferred
embodiment as shown in the plan view of FIG. 3, the
aperture-forming protrusion structure 30 is located in cover 11
directly over pouch 22 so that, when opened, nozzle aperture 32
communicates directly with the contents of pouch 22.
[0133] In accordance with the present invention, as preferably
embodied, dispenser package 10 includes a cap member 110 formed as
an integral part of cover 11. Advantageously, cap member 110 is
removable from cover 11 along a line.
[0134] It will be seen that the cap 110 protects the breakaway tip
structure 30 from inadvertently breaking off during shipping and
handling prior to use, as well as providing a means to reclose the
package after opening, i.e., after the protrusion tip member 34 is
broken off. Thus, cap 110 protects the remaining contents of the
package after each use, permitting multiple uses. The advantage of
the tethered embodiment of the invention is that it costs
practically nothing, acts as a side pressure spring to maintain the
cap on the neck 32 at the opening, acts as a grasping member to
assist removal of the cap for each subsequent use, and prevents
loss of the cap before the contents of the package have been fully
dispensed and the package is ready to be disposed of. Further
details of the cap are explained below.
[0135] In practically all cases, however, it is believed preferable
to provide the two-stage breakaway tip configuration since the
first projecting cylindrical formation 32 acts as a nozzle yielding
directionally controllable product dispensation, after the tip,
i.e., second protrusion 34, is broken off. Low and medium viscosity
flowable products tend to squirt "side-ways" or spurt in
non-controllable directions, when passing through an aperture
formed in the plane of the cover member. Furthermore, elevating the
breakaway tip from the surface of the cover member greatly enhances
its ease of use with no practical increase in manufacturing
cost.
[0136] In use, as here preferably embodied, package 10 preferably
is positioned so that pouch or chamber 22 rests in the palm of the
hand with the thumb resting on the cover 11. The thumb or finger of
the holding hand, or the user's other hand, if desired, may then be
used to apply a light finger pressure against the side of
protrusion tip 34, i.e., the breakaway tip, thereby causing tip 34
to break off, leaving an open neck or nozzle-like aperture 32.
[0137] Once tip 34 is removed and the package thereby opened, the
contents of the package 10 may be expelled. This method of use
depends on the type of substance contained in the package and where
the user would like to place the contents. For example, if the
package contains toothpaste, the open nozzle 32 preferably would be
placed over a tooth brush, whereupon gentle squeezing of the
package 10 will force the toothpaste onto the toothbrush. If the
contents of the package are intended to be placed directly into the
user's mouth, or the mouth of a patient, such as for oral medicine
or mouthwash, the open nozzle 32 then may be placed directly into
the mouth and a portion, or all, of the contents may then be
directed into the mouth by squeezing the package. When the desired
quantity of the contents of the package has been expelled, if some
contents remain, package 10 may then be reclosed for future use by
placing cap 110 over the open nozzle 32.
[0138] As previously mentioned, as here preferably embodied,
package 10 further includes a cap 110. While cap 110 may be formed
separately from the other elements of package 10, in the preferred
embodiment cap 110 is integrally formed with and is at least
partially detachable from the relatively stiff sheet 12 forming
cover 11, as shown in FIGS. 1-3, 9-10, 15-18, 22-23d, 29a-c, 32-35,
38-40, and 42-47, for example.
[0139] As shown in FIGS. 1-3 and 8-9, cap 110 preferably is located
at one corner in cover 11 so as to overhang pouch 22. A cut line
114 allows cap 110 to be easily removed from cover 11.
Advantageously, as best seen in FIG. 10, cut line 114 extends only
partially along the edge of cover 11 so as to provide a tether 130
to maintain cap 110 attached to package 10 even after the cap is
paced over either the aperture-forming structure 30 or over the
open nozzle 32.
[0140] Cap 110 typically is unthreaded and is dimensioned to fit
smoothly, yet securely, over the necked protrusion 32, which
preferably also is smooth and unthreaded, both before and after
removal of tip 34. Cap 110 has a base 126 which lies flat against
the top of cover 11. Tether 130 has several advantages. First, it
has been discovered that the tether 130 acts as a spring pressing
the cap against the sidewall of the necked protrusion 32, thereby
assisting to hold cap 110 in place when it is placed over the
necked protrusion 32. Additionally, tether 130 provides the added
benefit of preventing the cap 110 from becoming lost and allows the
user to grip the tether 130 to assist in removal of the cap 130
from the aperture-forming structure 30 or from open nozzle 32.
[0141] Cap 110 of the present invention can be designed in several
different embodiments. For example, in the embodiment shown in
FIGS. 10 and 11, the cap can be formed from a hollow punch member
120 that forces the material into a hollow female member 122 with a
central protrusion 124 to form a cap with a central plug 126.
[0142] An alternative to the embodiment shown in FIGS. 1-4 is shown
in FIGS. 2a and 3a. As shown, the container 10a has generally the
same configuration as container 10 depicted in FIGS. 1-3 is made of
the same materials. Specifically, pouch 22a is formed between a
flexible sheet 18a and the very thin skin like sheet 12a, 14a, in
which a flowable substance is contained. Unlike the previous
embodiment, the aperture-forming protrusion structure 30a is formed
on the underside of the flat sheet 18. Similarly, the cap 110a is
formed on the underside of the sheet 18. With such an arrangement,
not only are the neck and tip protrusions 32a, 34a of the
protrusion structure 30a protected from accidental rupture, but
also the container 10a is provided with a low cost flexible cover.
In order for the protrusion structure 30a to be in fluid
communication with the contents of the pouch 22a, the pouch 22a is
provided with a channel 11b which communicates with the protrusion
structure.
[0143] It will be understood that the aperture-forming protrusion
structure 30 may be made by a variety of methods and apparatus. In
accordance with the present invention, however, as preferably
embodied, a web of thermoformable material to be formed into cover
11 is first heated to a sufficient forming temperature. The web is
then formed into the hollow cylindrical protrusion 32 with a closed
end. The closed end portion of the cylinder 32 is then further
deformed in its central section to create the tip 34. At the moment
tip 34 is completely formed, the intersection of the base of tip 34
and cylinder 32 is compressed, reducing its thickness, to thereby
create a fault line extending about the periphery of the base of
tip 34.
[0144] Also in accordance with the present invention, as here
preferably embodied, aperture-forming protrusion 30 is formed by
means of a self-centering and self-aligning male and female punch
and die apparatus, indicated generally at 40, as shown in FIGS.
4-7.
[0145] Apparatus 40 includes feed rollers 42 or other means to
advance the web or film "F" of thermoformable material into a
heating station 44 where a heater block 46 advances against the
film to press the sheet against a stationary heater block 48, which
is temperature controlled by a thermocouple 50 and supplied with
necessary power at connection 51. An air cylinder 52 provides the
driving force to move the heater block 46 by means of shaft 54. The
heater block 46 includes two heaters energized by an appropriate
power source 58.
[0146] A two-stage punch member 60 includes a first male punch 62
formed as a generally cylindrical hollow punch having a
substantially flat end surface 64 at its operative end. When the
first punch member is advanced, the end surface 64 engages and
deforms the heated sheet of thermoformable, preferably plastic,
material F, compressing the plastic against a similarly shaped,
oppositely mounted, generally cylindrical hollow anvil member 66
movable in a bore 68 of a support 70. The anvil 66 has an end face
71. The first punch 62 has a clearance fit with the bore 68 so it
can be moved therein to confront the end face of the anvil 66.
Anvil 66 has an aperture bore 67 formed as part of its hollow
portion.
[0147] Anvil 66 is part of a spring-loaded rocker member 72,
preferably supported by a ball-shaped member 74, or other similarly
shaped curved rocker device, in a larger base opening 75 so as to
be both resilient and self-centering and self-aligning with punch
member 60. Although rocker 74 is preferably curved or ball-shaped,
a relatively flat surface in spring-mounted engagement with the
base of adjustable mechanism 89 also serves to self-center the
aperture opening 67 of anvil member 66 with respect to
frusto-conical surface 84 and bevelled surface 83 of second punch
80, more fully described hereinafter. The peripheral edge or rim of
aperture 67 in anvil 66 is smaller than the bore of punch 62 to
create an internal shoulder 76 when the opposing substantially flat
end surfaces 64, 71 of the hollow cylindrical punch member 62 and
the anvil member 66 are brought together. The anvil and first punch
are preferably made of hardened steel.
[0148] In use, at the end of the first stage of the formation of
the aperture-forming protrusion 30, shown in FIG. 5, the plastic
web F is formed into a projecting, closed end, hollow generally
cylindrical drum-like shape, with the plastic web stretched across
the end of the first generally cylindrical hollow punch, and
clamped between the opposed facing end surfaces 64, 71 of the punch
and anvil members.
[0149] A second punch member 80 is mounted for travel within a
hollow bore 81 and beyond the end face 64 of the first punch member
62. The second punch member 80 includes a shaft 82 whose operative
end surface includes a shallow bevel 83, advantageously on the
order of 450, terminating into a conically-shaped portion 84 with a
flat end face 85 forming a frusto-conically shaped tip, indicated
generally at 86. The second punch member and its bevel 83 advances
into controlled engagement with the internal peripheral edge of the
shoulder 76 formed at the opposed end surfaces 64, 71 of the first
punch 62 and anvil 66.
[0150] In one aspect of the present invention, as preferably
embodied, the second punch member 80 can be constructed in multiple
parts. For example, each of the frusto-conical and beveled portions
84, 83 may be formed separately and removably attached to the
leading end surface of the shaft 82, such as by threaded
connections. Alternatively, shaft 82 and tip portions 83, 84 may be
formed as an integral unit. The second punch member is driven by
air cylinder 87.
[0151] It will be understood from the foregoing that the full
length of the frusto-conical end 86 of punch 80 continues to travel
past the formed internal shoulder 76 and into the anvil aperture 67
until such time as bevel surface 83 is brought into accurately
controlled cooperating engagement with the internal peripheral edge
of the internal shoulder 76 formed by the opposed end surfaces 64,
71 of the first punch 62 and the anvil 66. Advancement of punch
surface 83 against shoulder 76 is accurately controlled by
micrometer punch adjustment mechanism 88 and anvil adjustable stop
mechanism 89.
[0152] The still-heated closed end of the initially formed hollow
cylinder 32, i.e., the first drum-like protrusion of the
aperture-forming structure 30 is, in a second stage, further formed
into a substantially cylindrical or frusto-conically shaped tip 34,
i.e., the second protrusion of the aperture-forming structure 30,
by the advancing second punch member until the shallow bevelled
surface 83 of punch 80 engages the plastic sheet. At that time, the
second punch surface 83 controllably compresses, cools and sets the
plastic web F against the internal peripherally extending edge
formed at shoulder 76 of the anvil to reduce the thickness, and
thereby weaken, the wall of the plastic at the locus of the
peripheral edge so as to form a narrow, peripherally extending
indentation 100, known as a rupture or fault line, at the base of
tip protrusion 34. It will be seen that fault line 100 permits the
tip protrusion 34 to be readily broken away by means of only light
lateral pressure to thereby form a nozzle-like outlet opening at
neck protrusion 32.
[0153] It should be noted that changes in the dimensions of the
beveled end 86 and the anvil 66 are within the scope of the present
invention. For example, it is often desirable to produce a fine
stream of the contents of a container, such as motor oil.
Consequently, the opening formed by the base of the tip protrusion
34 must be relatively small, such as shown in FIG. 8a. To form such
a aperture-forming protrusion structure 30, the end 86 is
elongated, and the beveled surface 83 is positioned closer to the
distal end 85. Furthermore, the anvil 66 is provided with a
relatively narrow opening. Consequently, as shown in FIG. 7a, the
fault line 100 and the breakaway tip 34a are smaller.
Alternatively, the entire punch 82 and, therefore, protrusion
structure 30 is made narrower.
[0154] In other applications, where the contents of a container are
large particles, such as cat food, the opening must be relatively
large, such as shown in FIG. 7b. To achieve a larger opening, the
entire punch 82 and, therefore, protrusion structure 30 are made
wider. Alternatively, the fault line 100 and the break away tip 34
are made larger.
[0155] In an alternate embodiment illustrated in FIGS. 12 and 13, a
single punch 90 with a truncated end 92 can be used. The single
punch 90 includes a bevelled surface 94 which engages the film or
web F of thermoplastic material to form the generally
frusto-conical hollow tip protrusion 34. As here embodied,
thermoplastic web F is first clamped between shoulder plate 96 and
face 97 of an outer punch member similar to punch 62. Thereafter,
punch 90 advances, whereupon end 94 forms web F into frusto-conical
tip 34, as shown as FIG. 13. As alternatively embodied, however, as
best seen in FIG. 12, upon completion of the formation of tip 34,
the peripheral edge 76a of anvil member 70 engages and compresses
the outer surface of the frusto-conical wall of tip 34 to create a
peripherally extending fault line 100a along the projecting surface
of tip 34 between its base and apex.
[0156] In yet another alternative embodiment illustrated in FIGS.
12a and 13a, a single punch 91 with a beveled, truncated end 93 can
be used to form the generally frusto-conical hollow tip protrusion
31. The single punch 91 engages the film or web F of thermoplastic
material with the beveled surface 93. As with the embodiment shown
in FIGS. 13 and 14, the thermoplastic web F is first clamped
between stop plate 95 and clamp means 98 of an outer punch member.
Thereafter, punch 91 advances, whereupon end 93 forms web F into
the frusto-conical tip 31. As best shown in FIG. 13a, contact of
the peripheral edge 77 of angle member 71 compresses the outer
surface of the frusto-conical tip 31 to create a peripherally
extending fault line 10b. In contrast to the embodiment shown in
FIGS. 12 and 13, the stop plate 95 is situated adjacent the shaft
of the punch 91, below the beveled, truncated end 93. Consequently,
the thermoplastic web F is formed around the beveled end 93 as well
as the right cylindrical shaft 91a. As can best be seen in FIG.
13a, the resulting frusto-conical tip 31 has a breakaway tip 35, a
permanent projection 33, and a bright cylindrical section 33a. The
right cylindrical section 33a is provided so a cap may be securely
engaged with the tip 31.
[0157] In an alternative embodiment illustrated in FIG. 12b, a
single punch 91B has a spherical tip 93A. The spherical tip 93A
engages the thermoplastic web F to form a hollow mound protrusion.
As embodied, the thermoplastic web F is first clamp beneath a stop
plate 95A. Thereafter, punch 91B advances, whereupon the spherical
end 93A forms web F into a hollow mound. Furthermore, the punch 91B
is advanced forwards anvil 71A until the outer surface of the web F
engages the peripheral edge 77A of anvil member 71A, thereby
creating a fault line that extends around the tip of the mound
structures. It has been found that the spherical tip 93A allows for
self alignment of the punch 91B as the web F engages the peripheral
edge 77A of the anvil 71A.
[0158] Referring now more particularly to FIGS. 15-18 of the
accompanying drawings, there is illustrated an alternate embodiment
of the dispenser package of the present invention, indicated
generally by reference manual 200. As here embodied, cover 211
includes a lateral extension 211a which extends beyond one end of
the container pouch 222 and both the aperture-forming structure 230
and reclosure cap member 240 are formed in cover extension 211a. A
shallow channel member 250 communicates aperture-forming structure
230 with the contents of pouch 222. Further alternatively, as shown
in FIG. 17, lateral extension 211a of cover 211 is formed on an
angle with respect to cover 11 so as to slope toward the pouch side
of cover 11.
[0159] It has been found that the embodiments of FIG. 14-17 are
advantageous in that they facilitate dispensing the contents of the
package onto a surface, such as butter or cream cheese onto a slice
of bread or toothpaste onto a toothbrush.
[0160] Referring now more particularly to FIGS. 18-20, there are
shown several other alternative embodiments of the cap member of
the present invention. Thus, as shown at FIG. 18, the top of
resealing cap 110 may include bristles or nubs to function as a
brush member; as shown in FIG. 19, the top of cap 110 may have a
flattened surface 270 capable of functioning as a spreading tool;
as shown in FIGS. 20a-d, cap 110 may be open-ended and have a
shaped edge configuration, such as shown at 280, 281, 282, 283,
respectively, so that the contents of the package may be expelled
in a shaped stream.
[0161] With reference to FIGS. 21a-b and 22a-c, an alternate
embodiment of the present invention will now be shown and
described. In accordance with this alternate embodiment, an
independent thermoformed unit is used to create an outlet aperture
in a container. The independent thermoformed unit may take the form
of a reclosable outlet forming structure 300. The reclosable outlet
forming structure 300 may generally comprise a cap 310, a tether
320, a base 330, and a breakaway outlet tip 340. Cap 310 may be
connected to base 330 via tether 320. Score 325 facilitates
separation of the cap 310 from structure 300. The reclosable outlet
forming structure 300 may have a pre-applied adhesive or sealant in
the area surrounding the base 330 to facilitate application of the
structure 300 to a container, such as milk container 302. As such,
the structure 300 may be sealably or adhesively attached to any
surface of a container requiring the subject outlet. In particular,
the structure 300 may be sealed or adhered to the container in an
area surrounding a hole in the container, but not in the area of
the cap 310 or tether 320 which must be free of the container's
surface. It is to be understood that reclosable outlet forming
structure 300 may be attached to containers, such as milk carton
302, prior to filling. As such, the structure 302 may be applied to
a container when it is still a flat blank.
[0162] With reference to FIGS. 22a-d, use of the reclosable outlet
forming structure 300 will now be shown and described. With
reference to FIG. 22a, prior to shipping of the container 302, the
cap 310 may be placed over the outlet forming structure base 330
prior to removal of the breakaway tip 340 so as to assure that the
breakaway tip 340 does not accidentally break and the contents of
container 302 do not escape while the container 302 is in transit.
With reference to FIG. 23b, the cap 310 is removed from base 330 to
provide access to breakaway tip 340. The container at this point is
ready for opening. With reference to FIG. 23c, the breakaway tip
340 is then removed to create an opening 350. Opening 350 leads to
a hole (not shown) in container 302 to allow pouring the contents
of container 302 therethrough. With reference to FIG. 23a, the
reclosable outlet forming structure 300 may be resealed by simply
placing the cap 310 over base 330.
[0163] In one embodiment of the present invention, base 330 and tip
340 are cylindrical or substantially cylindrical, although it is to
be understood that other shapes may be used. In this embodiment,
the opening 350 is made of PET-PVC-BAREX. It is to be understood,
however, that other materials in accordance with the present
invention may be used.
[0164] As can be seen in FIG. 22d, the cylindrical outlet 330 and
opening 350 act a nozzle direct the flow of the contents of the
container 302 into a control stream.
[0165] With reference to FIGS. 23-26, a low profile breakaway tip
and cap in accordance with another embodiment of the present
invention is shown. In general, lowering the height of a breakaway
tip 360 will lower the possibility that the tip 360 may be
accidentally opened during transit or by handling. Lowering the
height of the breakaway tip makes it more difficult, however, to
grasp and remove the breakaway tip. This difficulty is alleviated
by creating undercuts or indents 370 in the sidewall of the
breakaway tip 360. These undercuts or indents 370 allows a user's
finger to hook and break away the tip 360 in a single motion. FIG.
25 is a perspective view of the low profile breakaway tip with the
removed breakaway tip shown in phantom. With continuing reference
to FIGS. 23-25, the undercuts or indents 370 are preferably
arranged in opposed positions to facilitate ease of use and
manufacture. It is to be understood that the number and location of
the undercuts/indents 370 may be varied. Once the breakaway tip 360
is removed from base 380, a cap 394 may be used to reclose the
opening (not shown) exposed by the removal of tip 360 in base 390.
Base indents 392 in base 380 are shaped and dimensioned to receive
opposed inward protrusions 396 of cap 394. These protrusions 394
snap into indents 392, thereby securing cap 390 to base 380. A
tether (not shown) may also be used to attach cap 390 to base
380.
[0166] As shown in FIGS. 23a and 24a, the base 390a may have
generally triangular cross-sectional area. Such a cross-sectional
area, may aid in the dispensing of various materials. Furthermore,
the relatively large bottom of the base 390a helps avoid accidental
toppling of a container.
[0167] It is also to be understood that this embodiment of the
present invention may be used in a wide variety of applications,
including dispensers for creamers, unit dose medications, salad
dressings, beauty aids, dental products, condiments, candy
confections, syrups, granular products, etc. It is also to be
understood that this embodiment of the present invention may be
manufactured by utilizing a male punch member in conjunction with a
self-centering and receding female anvil system, as previously
shown and described.
[0168] Although the use of a tether limits the rotation of a cap
pressed onto a base formation, a twist-lock or twist-threading
arrangement may also be used to secure the cap to the base. With
reference to FIG. 28, such an embodiment of the present invention
which utilizes a twist-lock or twist-threading arrangement 400 to
secure the cap 410 to the base formation 420 is shown. In this
arrangement, cap 410 has an inner protrusion 415 which engages cam
surface 430 of base 420. Upon rotation of cap 410 with respect to
base 420, inner protrusion 415 engages cam surface 430 to create a
twist-lock or twist-thread arrangement. It is to be understood that
a tether (not shown) may also be used in such an arrangement. Base
420 may also have a breakaway tip 425 attached thereto.
[0169] As an alternative to the breakaway tip and tethered cap
arrangement, the present invention also includes a tethered
plug/punch and scored surface arrangement as shown in FIGS. 28a-c,
29a-d and 30a-d. FIGS. 28a and 28b are perspective views of such an
embodiment of the present invention in which a tethered plug is
used to open and close a pre-scored surface. In this arrangement
450, a plug 460 is used to open a pre-scored surface 470 of outlet
480. In this embodiment, the score is in the form of an interrupted
circle, although it is to be understood that other types of scored
surfaces, such as those shown in FIGS. 29a-d, may also be used.
FIGS. 28b and 28c depict a flap 485 which is created when plug 460
is used to penetrate the scored surface 470. A tether 490 may also
be created through the use of a score 495 in arrangement 450. Plug
460, which may be connected to arrangement 450 via this tether 490,
may also be used as a cork to close the outlet hole. As such, plug
460 may be used both as a plug and as an opening tool to create
and/or plug an aperture in the pre-scored surface. In this
embodiment, plug 460 has a conical shape, although it is to be
understood that other shapes may be used. Similarly, as shown in
FIGS. 28a and 29a-d, the score may have a partially circular shape,
a V-shape, an X-shape, a star shape, or box shape, although it is
to be understood that other patterns may also be utilized.
Depending on the shape of the scored surface, the flap created by
the penetration of plug 460 will differ. For example, the
penetration of scored V-shaped surface 490 will create a flap 491;
the penetration of scored X-shaped surface 492 will create a flap
493; the penetration of scored star-shaped surface 494 will create
a flap 495; and the penetration of a scored surface 496 will create
a rectangular-shaped flap 497.
[0170] An alternative embodiment of the present invention will now
be discussed with reference to FIGS. 31-36. In accordance with this
alternative embodiment, a container 500 is provided with a
reclosable outlet forming structure 510. More specifically, the
outlet former structure 510 comprises a curvilinear dome or mound
530 and a dual purpose punch/plug 520. As will be apparent to one
of skill in the art, the container 500 includes a hole, not shown,
over which the mound 530 is secured. Because the punch/plug 520
must be lifted and inverted for insertion into the scored area 532,
it must not be sealed to the container 500. On the other hand, the
mound 530 portion of the outlet forming structure 510 must be
securely adhered over the hole in the container 500.
[0171] As can best be seen in FIG. 34, the outlet forming structure
510 comprises a layer of foil 534 laminated to the plastic forming
the outlet forming structure 510. The portion of the foil 534
underneath the mound 530 should be unsupported other than the
adhesive used to secure it to the mound 530. It should also be
noted that the foil 534 is secured to the container 500, about the
hole in the container 500, so that the contents do not leak out
beneath the outlet forming structure 510. The foil laminated
adhesive should be one that gives adequate adhesion but sets up
with minimal tensile strength of its own. In alternative
embodiments, the adhesive may approach being brittle.
[0172] The mound 530 further includes a fault line pattern or
scored pattern 532. The fault lines 532 may take on any number of
patterns, such as those shown in FIGS. 29a-d. As shown in FIGS. 35
and 36, the foil 534 is laminated to the entire surface of the
mound 530 and preferably, is not scored. In an alternative
embodiment, the adhesive may be omitted from the fault line pattern
532.
[0173] The punch/plug 520 is secured to the outlet forming
structure 510 via a tether 524. The tether 524 is created by a cut
522 through the foil/plastic laminate. As can best be seen in FIG.
32, the cut 522 preferably takes a curvilinear path, following the
periphery of the outlet forming structure 510. Such a cut 522
provides an elongated tether 524.
[0174] In operation, the punch/plug 520 is firmly pushed into the
fault line pattern 532 to rupture the scored mound 530. This
operation is best shown in FIG. 35. Having forced the punch/plug
520 through the scored area 532 of the mound 530, an opening for
dispensing the contents of the container 500 is formed. The
punch/plug 520 is removed from the mound 530 so that contents of
the container 500 may be dispensed. Because the scored area 532 has
been deformed to the shape of the punch/plug 520, the punch/plug
520 may be reinserted into the scored area 532, thereby resealing
the container 500.
[0175] In an alternative embodiment, however, the foil layer 534
may span the hollow base of the mound 530 by being laminated only
to the periphery of the mound. Of course, in such an embodiment,
the punch/plug 520 must be long enough to extend past the plane of
the foil 534 so that the foil 534 may be punctured. By wobbling the
punch/plug 520 while inserted into the mound 530, the opening in
the foil is enlarged.
[0176] It should be noted that the mound 530 strengthens the outlet
forming structure 510. Furthermore, the shape of the mound 530
provides a nozzle function, directing the contents of the container
500 in an even stream. Depending upon the contents of the container
500, the dimensions and shape of the mound 530 may be altered to
provide the desired flow.
[0177] The outlet forming structure 510 of FIGS. 31-36 are
preferably manufactured with a punch similar to that described with
reference to FIG. 12b. Of course, the tip of the punch need not be
spherical, but rather may be elliptical, parabolic, or any
curvilinear shape. Furthermore, it is preferred that the foil and
plastic be laminated into a single web prior to the formation of
the mound be the punch. Thus, the dimensions of the mound, as
defined by the shape of the punch tip, will be limited only be the
physical properties of the materials used.
[0178] In an alternative embodiment, which will now be described
with reference to FIGS. 37-38, a reclosable outlet forming
structure 610 according to the present invention is utilized with a
flexible plasti-foil pouch 600. In general, the foil pouch 600 is
formed by folding a generally rectangular shaped piece of the foil
plastic combination in half and sealing the three open edges
thereof. A reclosable outlet forming structure 610 is mounted on
the seamless end 605 of the pouch 600. The outlet forming structure
610, which is sealed to the seamless end of the pouch 600 by
applying an adhesive around a periphery of the base 612, covers a
hole, not shown, in the pouch 600.
[0179] The outlet forming structure 610 may be of any type
previously disclosed above, such as those described with reference
to FIGS. 1-3, 8-9, 13, and 13a. In a preferred embodiment, as shown
in FIGS. 37 and 38, the outlet forming structure 610 includes an
aperture forming protrusion 630. More specifically, the aperture
forming protrusion 630 includes a hollow cylindrical base 632 and a
break-away tip 634. A fault line 636 extends around the periphery
of the protrusion structure 630, permitting the breakaway tips 634
to be broken away from the base 632 in the tip 634. More
specifically, the fault line 636 is a narrowed, stress
concentrating area.
[0180] The outlet forming structure 610 also includes a cap 620.
The cap 620 is a hollow tapered member, which has an inside base
diameter slightly larger than the outside diameter of the base 632
of the protrusion structure 630. The cap 620 is secured to the
outlet forming structure 610 via a tether 624. The tether 624 is
formed by a cut 622 through the lower surface 612 of the outlet
forming structure 610. As can best be seen in FIG. 39, the
curvilinear cut 622 separates the cap 620 from the protrusion
structure 630 and follows the periphery of the base 612. By having
such a pattern, the cut 622 is relatively long and, consequently,
produces a relatively long tether 624. Due to the long tether 624
and the fact that the portion of the base 612 that supports the cap
620 is not fastened to the pouch 600, the cap 620 may be raised and
securely placed over the outlet forming structure 630.
[0181] In operation, a user applies sidewise finger pressure to the
protrusion tip 634, thereby causing it to break away from the
protrusion base 632 along a fault line 636. Because the protrusion
structure 630 is substantially hollow, an aperture, not shown, is
created. Furthermore, because the protrusion member 630 has been
affixed to the pouch 600 over a hole in the pouch, not shown, the
contents of the pouch 600 may be dispensed via the now opened
protrusion neck 632. The cap 620 is placed over the base 632 during
shipping, so that accidental rupturing of the fault line 636 is
prevented. Furthermore, cap 620 is placed over the base 632 to
reclose the package 600 when only a portion of the contents of the
package 600 has been dispensed.
[0182] In an alternative embodiment, shown in FIG. 39, the same
outlet forming structure 610 is secured to the side of pouch 640.
In this embodiment, the pouch 640 is formed from two generally
rectangular sheets of foil plastic laminate which are sealed
together around all four sides of each sheet. As with the previous
embodiment, the protrusion structure 630 is affixed to the pouch
640 over a hole, not shown, so the protrusion neck 632 is in fluid
communication with the contents of the pouch 640.
[0183] An alternative embodiment of the present invention employing
an outlet forming structure 610a disposed on a foil pouch 640a will
now be described with reference to FIGS. 37a, 38a, and 39a. Briefly
described, the outlet forming structure 610a is substantial the
same as the outlet forming structure described with reference to
FIGS. 37-39. Specifically, the outlet forming structure 610a
includes both a cap 620a and a protrusion member 630a. As best seen
in FIG. 39a, the foil pouch 640a includes a lap seam on the side
opposite the outlet forming structure 610a.
[0184] An alternative embodiment of the present invention will now
be described with reference to FIG. 40. A tethered punch/plug and
base member with a star shaped fault pattern manufactured as a unit
700 is shown. A tether 730 is connected to the base 710 at a
proximal end thereof, a ring structure 740 connected to a distal
end thereof, and a tapered punch/plug 760. The punch/plug 760 is
manufactured separately from the other components.
[0185] As shown, the ring structure 740 defines an opening 750. The
opening 750 is larger than the tip 762 of the punch/plug 760 yet
smaller than the base 764 of the punch/plug 760. Furthermore, the
punch/plug 760 includes a circumferential indentation 766. The
indentation 766 is formed on the punch/plug 760 just below a point
where the outside diameter of the punch/plug 760 becomes larger
than the inside diameter of the opening 750.
[0186] Therefore, once the components have been separately
manufactured, the punch/plug 760 is snapped into the opening 750.
When snapped into the opening 750, the tapered punch/plug 760
causes the slightly elastic ring structure 740 to expand until the
ring structure 740 reaches the indentation 766. Upon reaching the
indentation 766, the ring structure 740 snaps into the indentation
766. Consequently, the punch/plug 760 becomes connected to the ring
structure 740 and the other components.
[0187] In use, as shown in FIG. 40a, the punch/plug 760 is used to
puncture the scored section 722 of the protrusion structure 720.
Such operation is described in greater detail with reference to
FIGS. 28-30d.
[0188] Turning now to FIG. 41, one embodiment for manufacturing a
reclosable outlet forming structure according to the present
invention is shown. Specifically, a pair of reclosable outlet
forming structures 870 and 880 are formed from the same piece of
thermoplastic web F. Each reclosable outlet forming structure 870,
880 comprises a protrusion structure 872, 882 as well as cap 874,
884, respectively. As in the previously disclosed embodiments, each
cap 874, 884 is connected to the corresponding protruding structure
870, 880 via a tether 876, 886.
[0189] It is to be understood that the mating, horse-shoe
arrangement of the outlet forming structures 870, 880 provides
several benefits, such as reclining wasted portions of the web F,
and that the manufacturing agreement may be repeated along the
length of the web F.
[0190] Turning now to FIGS. 42-44, an alternative embodiment of the
present invention is shown. Initially, it should be noted that the
container 1000 shown is made of similar materials as described
above with reference to FIG. 1-3.
[0191] The container 1000 comprises a first deformable pouch 1010
and a second deformable 1020. The two pouches 1010, 1020 are joined
by a shallow conduit 1030. The deformable pouches 1010, 1020, as
well as the joining conduit 1030, are sealed by a generally flat
sheet 1040 of thermoformable plastic material. A hollow protrusion
1050 is integrally formed with the flat sheet of thermoformable
plastic 1040. The hollow protrusion 1050 extends from the flat
sheet 1040. The protrusion 1050 is directly above and in fluid
communication with the conduit 1030. The container 1000 further
includes a punch/cap 1060.
[0192] As can best be seen in FIG. 43, the hollow protrusion 1050
has scores or fault lines 1055 on the top face thereof. Despite
these fault lines 1055, which weaken the protrusion 1050, the
container 1000 remains sealed. Further shown in FIG. 46, the
punch/cap 1060 is partially separated from the remainder of the
container 1000 by cut 1062. The cut 1062 which parallels one
peripheral edge of the container 1000 creates a tether 1064.
[0193] In order to open the container 1000, the punch/cap 1060 is
positioned over the protrusion 1050. The punch/cap 1060, and more
specifically the pointed end 1066 of the punch/cap 1060 is forced
through the score or fault lines 1055, thereby opening the hollow
protrusion 1050. When punch/cap 1060 is removed from the hollow
protrusion 1050, an opening, not shown, exists. The opening is
formed by the permanent deformation of the portion of the
protrusion member 1050 between the fault lines 1055. By inverting
the container 1000 and gently squeezing either or both of the
pouches 1010, 1020 the material contained within the pouches is
dispensed via the opening in the protrusion 1050.
[0194] It should be noted that in the preferred embodiment the
protrusion 1050 is placed directly above the conduit 1030. As a
result, the contents of the pouches 1010, 1020 can be dispensed in
a controlled manner. Specifically, the shallow conduit 1030
provides resistance to the flowing contents so that the contents do
not spout from the opened protrusion 1050 uncontrollably,
particularly when the protrusion 1050 is initially punctured.
[0195] As shown in FIG. 44, should less than all of the material
contained within the pouch 1010, 1020 be dispensed, the container
1000 may be reclosed. Specifically, the punch/cap 1060 is inverted
by twisting the tether 1064. Because the punch/cap 1060 is hollow,
having an inside diameter substantially the same as or slightly
larger than the outside diameter of the protrusion 1050, the
punch/cap 1060 can be securely placed on the protrusion 1050.
[0196] With regard to the embodiment of FIGS. 42-44, it will be
apparent to one skilled in the art that the invention is not
limited by the type of outlet forming structure utilized.
Specifically, any combination of break away tip, scored protrusion
member, punch, plug, and cap may be employed. Furthermore, it
should be understood that the particular shape of the pouches may
vary according to the properties of the contents held therein.
[0197] An alternative embodiment of the present invention will now
be described with reference to FIGS. 45-47. As shown in FIG. 45, an
outlet forming structure 1070 comprises a cap member 1072 and an
aperture forming protrusion 1074. As with the embodiments discussed
above, the cap member 1072 is connected to the aperture forming
structure 1074 by a tether 1076. As can be seen, both the cap
member 1072 and the aperture forming structure 1074 are formed in a
curvilinear base 1078.
[0198] Because the outlet forming structure 1070 is formed in a
curvilinear base 1078, it may be positioned on a container 1080
having a similar curvilinear surface. As shown in FIGS. 46a-c, one
such container 1080 is generally spherical and formed in two halves
1082, 1084. The two halves 1082, 1084 are joined at one point along
their circumferences, and are therefore hingeably connected. One
half 1084 of the container 1080 includes an aperture 1086 formed
therein.
[0199] In operation, as shown in FIG. 47, the outlet forming
structure 1070 is affixed to the container 1080 such that the
aperture forming structure 1074 is in alignment with the aperture
1086 in the container 1080. As further depicted in FIG. 47, the cap
member 1072, shown in a sectional view, may be positioned over the
aperture forming structure 1074, thereby protecting it and sealing
the container 180. It is to be understood that the shape of the
container 1080 is merely representative of those that may be
employed with the present invention, as the outlet forming
structure may be formed on a curvilinear base having virtually any
shape.
[0200] Another alternative embodiment of the present invention will
now be described with reference to FIGS. 48-51. The container 1090
generally comprises a rectangular sheet 1091 of thermoformable
material. At the center of the rectangular sheet 1091 is an
aperture forming structure 1092, having a base and break away tip
as described above with reference to the prior embodiments. On
either side of the aperture forming structure 1092 are pouches 1098
formed on the underside of the sheet 1091 for holding any flowable
substance. The pouches 1098 are in fluid communication with the
aperture forming structure 1092.
[0201] Also formed in the rectangular sheet 1091 of thermoformable
material is a cap member 1094. The cap member 1094 is preferably
formed in one corner of the rectangular sheet 1091 and attached to
the container 1090 via a tether 1096. The tether 1096 is formed by
a cut 1097 extending along the perimeter of the container 1090.
[0202] The container 1090 may be folded generally in half along
bending grooves 2006 disposed on either side of the aperture
forming structure 1092. Specifically, the ends of the container
1090 are brought together as depicted by arrows "A" in FIG. 49.
Once the ends are brought together, a female package tie 2000 and a
male package tie 2002, both of which are integrally formed in the
sheet of thermoformable material 1091, are brought into
engagement.
[0203] Engagement of the female package tie 2000 and the male
package tie 2002 hold the container 1090 in the configuration as
shown in FIGS. 50 and 51. In operation, lateral finger pressure on
the tip of the aperture forming structure 1092 causes a fault line
to rupture, thereby forming an aperture in the aperture forming
structure 1092. Thus, the contents of the container 1090 may be
dispensed from the aperture. As shown in FIG. 51, the cap member
1094 may be placed over the aperture forming structure 1092,
thereby preventing accidental rupturing of the fault line or
accidental dispensing of the contents after the tip of the aperture
forming structure 1092 has been removed.
[0204] Another alternative embodiment of the present invention will
now be described with reference to FIGS. 52-54. As shown in FIG.
52, an aperture forming structure 2016 according to the present
invention may be positioned on a treated paper board tube 2012,
thereby forming a sealed container 2010. The aperture forming
structure 2016 comprises a generally hollow frusto-conical portion
2018, a hollow cylindrical portion 2019, and a breakaway tip 2020.
Integrally formed with the aperture forming structure 2016 is a cap
member 2022 and an associated tether 2024. As can best be seen in
FIG. 54, the tether 2024 is formed by a curvilinear cut which
allows the cap member 2022 to be partially separated from the
aperture forming structure 2016 so that the cap member 2022 may be
positioned over the cylindrical portion 2019 and the breakaway tip
2020. Because the cap member 2022 has an inside diameter slightly
larger than the outside diameter of the cylindrical portion 2019,
the cap member 2022 fits snugly thereon, thereby sealing the
container 2010.
[0205] As with the previously described embodiments, in operation,
lateral pressure on the breakaway tip 2020 causes it to separate
from the rest of the aperture forming structure 2016, thereby
forming an aperture into the generally hollow aperture forming
structure 2016. Thus, the contents of the container 2010 may be
dispensed therefrom.
[0206] It will remain understood by those skilled in the art that
the present invention in its broader aspects is not limited to the
particular embodiments shown and described herein, and that
variations may be made without departing from the principles of the
invention and without sacrificing its chief advantages.
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