U.S. patent application number 10/456207 was filed with the patent office on 2003-12-18 for separable containers arranged in arrays with integrally formed lids.
Invention is credited to Handel, Gerald J. Van, Whitmore, Rebecca E..
Application Number | 20030230582 10/456207 |
Document ID | / |
Family ID | 29736650 |
Filed Date | 2003-12-18 |
United States Patent
Application |
20030230582 |
Kind Code |
A1 |
Whitmore, Rebecca E. ; et
al. |
December 18, 2003 |
Separable containers arranged in arrays with integrally formed
lids
Abstract
An integrally formed ensemble of interconnected, separable
containers and associated lids is adapted for use as disposable
containers for condiments, sauces, and the like. The interconnected
assembly typically includes a first plurality of containers
arranged in a first linear array and a second plurality of
containers arranged in a second linear array wherein the first
linear array and the second linear array are secured to each other
by way of a plurality of tear portions. First and second
pluralities of lids are hinged to the containers and outwardly
disposed with respect thereto such that the lids and containers are
balanced during a fill operation.
Inventors: |
Whitmore, Rebecca E.;
(Chilton, WI) ; Handel, Gerald J. Van; (Neenah,
WI) |
Correspondence
Address: |
Michael W. Ferrell, Esq.
Ferrells, PLLC
P.O. Box 312
Clifton
VA
20124-1706
US
|
Family ID: |
29736650 |
Appl. No.: |
10/456207 |
Filed: |
June 6, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60389533 |
Jun 18, 2002 |
|
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Current U.S.
Class: |
220/507 |
Current CPC
Class: |
B65D 43/162 20130101;
B65D 1/30 20130101 |
Class at
Publication: |
220/507 |
International
Class: |
B65D 001/24; B65D
001/36 |
Claims
What is claimed is:
1. An integrally formed ensemble of interconnected separable
containers and associated lids comprising: (a) a first plurality of
containers arranged in a first linear array each container
comprising a cup and a lid adjoined thereto, said containers being
separably adjoined to each other by a first plurality of tear
portions, each of said first plurality of containers having an
upper cup aperture, a cup sidewall and a cup bottom and further
including means for securing its associated lid about its upper cup
aperture; (b) a second plurality of containers arranged in a second
linear array, each container comprising a cup and a lid adjoined
thereto, said containers being separably adjoined to each other by
a second plurality of tear portions, each of said second plurality
of containers having an upper cup aperture, a cup sidewall and a
cup bottom and including means for securing its associated lid
about its upper cup aperture; wherein said first linear array of
said first plurality of containers is secured to said second linear
array of said second plurality of containers by way of a third
plurality of tear portions arranged along a medial axis between
said first linear array of said first plurality of containers and
said second linear array of said second plurality of containers;
(c) there being thus provided a first plurality of lids hinged to
said first plurality of cups, said first plurality of lids being
arranged in a third linear array, generally parallel to the medial
axis between the container arrays, said third linear array of said
first plurality of lids being generally disposed and hinged along
the sides of the first plurality of containers opposite to the
sides adjacent the medial axis between said first linear array of
said first plurality of containers and said second linear array of
said second plurality of containers; each of said first plurality
of lids being adapted to cooperate with the means for securing it
to its associated cups of the first plurality of containers to
provide sealed cup, lid assemblies upon pivotal motion of the lid
about its hinge to the upper cup aperture of its associated cup of
the first plurality of containers; (d) and there being thus further
provided a second plurality of lids hinged to said second plurality
of containers, said second plurality of lids being arranged in a
fourth linear array generally parallel to the medial axis between
the container arrays, said fourth linear array of said second
plurality of lids being generally disposed along the sides of the
second plurality of containers opposite to the sides adjacent the
medial axis between said first linear array of said first plurality
of containers and said second linear array of said second plurality
of containers; each of said second plurality of lids being adapted
to cooperate with the means for securing it to its associated cup
of the second plurality of containers to provide sealed cup, lid
assemblies upon pivotal motion of the lid about its hinge to the
upper cup aperture of its associated cup of the second plurality of
containers, the third linear array of said first plurality of lids
and the fourth linear array of said second plurality of lids being
thus generally distally and symmetrically disposed with respect to
the medial axis between the first linear array of the first
plurality of containers and the second linear array of the second
plurality of containers.
2. The integrally formed ensemble according to claim 1, further
comprising a fourth plurality of tearable portions connecting said
first plurality of lids to each other and a fifth plurality of
tearable portions connecting said second plurality of lids to each
other.
3. The integrally formed ensemble according to claim 2, wherein
each of said first and second plurality of lids has a tab portion
projecting outwardly with respect to said medial axis of the
ensemble and wherein the tabs of said first plurality of lids are
linearly offset with respect to the tabs of said second plurality
of lids and configured such that the tabs of said first and second
plurality of lids will lie along the medial axis adjacent each
other when the first and second plurality of lids are pivoted to
the medial axis.
4. The integrally formed ensemble according to claim 1, made from a
thermoplastic composition comprising a polystyrene polymer
composition.
5. The integrally formed ensemble according to claim 4, wherein
said polystyrene polymer composition comprises high impact
polystyrene.
6. The integrally formed ensemble according to claim 4, wherein
said polystyrene polymer composition comprises rubberized
polystyrene.
7. The integrally formed ensemble according to claim 4, wherein
said polystyrene polymer composition is oriented polystyrene.
8. The integrally formed ensemble according to claim 1, made from a
thermoplastic composition comprising a polyolefin polymer.
9. The integrally formed ensemble according to claim 8, wherein
said polyolefin polymer is polypropylene.
10. The integrally formed ensemble according to claim 8, wherein
said polyolefin polymer is polyethylene.
11. The integrally formed ensemble according to claim 1, made from
a thermoplastic composition comprising polyethylene
terephthalate.
12. The integrally formed ensemble according to claim 1, wherein
the upper cup apertures of said first and second plurality of
containers is substantially rectangular in shape.
13. The integrally formed ensemble according to claim 12, wherein
the bottom portion of each of said first and second plurality
containers are substantially rectangular in shape.
14. The integrally formed ensemble according to claim 1, wherein
said first and second plurality of containers have upwardly convex
cup bottom portions.
15. The integrally formed ensemble according to claim 1, wherein
said first and second plurality of lids are provided with recesses
configured to engage the cup bottoms of said first and second
plurality of containers.
16. The integrally formed ensemble according to claim 1, wherein
the means for securing associated lids about their corresponding
cups comprises a plurality of ridges disposed about the upper cup
apertures of said first and second plurality of containers.
17. The integrally formed ensemble according to claim 16, wherein
each of said first and second pluralities of lids are provided with
grooves configured to engage the ridges disposed about the upper
cup apertures of said first and second pluralities of
containers.
18. The integrally formed ensemble according to claim 17, wherein
said grooves and said ridges have mating profiles.
19. The integrally formed ensemble according to claim 1, wherein
said first and second pluralities of containers include a stacking
ledge of uniform width at an upper portion of their interiors.
20. The integrally formed ensemble according to claim 1, wherein
the upper cup apertures of said first and second plurality of
containers substantially define a planar region about said medial
axis.
21. The integrally formed ensemble according to claim 1, wherein
each container in said first and second pluralities of containers
has a fill volume of from about 1 to about 8 fluid ounces.
22. The integrally formed ensemble according to claim 21, wherein
each container in said first and second pluralities of containers
has a fill volume of from about 1 to about 4 fluid ounces.
23. The integrally formed ensemble according to claim 22, wherein
each container in said first and second pluralities of containers
have a fill volume of about 2 fluid ounces.
24. The integrally formed ensemble according to claim 1, wherein at
least one of said first or second plurality of tearable portions is
scored.
25. The integrally formed ensemble according to claim 1, wherein at
least one of said first or second tearable portions is
perforated.
26. The integrally formed ensemble according to claim 1, wherein
said lids are hinged to their associated cups by way of a perforate
scored hinge portion of the ensemble.
27. A thermoformed, integral ensemble of interconnected separable
cups and associated lids prepared from thermoplastic sheet material
comprising: (a) a first plurality of cups arranged in a first
linear array, connected to each other by a first plurality of tear
portions, each of said first plurality of cups having an upper cup
aperture, a cup sidewall and a cup bottom and further including
means for securing its associated lid about its upper cup aperture;
(b) a second plurality of cups arranged in a second linear array,
connected to each other by a second plurality of tear portions,
each of said second plurality of cups having an upper cup aperture,
a cup sidewall and a cup bottom and including means for securing
its associated lid about its upper cup aperture; wherein said first
linear array of said first plurality of cups is secured to said
second linear array of said second plurality of cups by way of a
third plurality of tear portions arranged along a medial axis
between said first linear array of said first plurality of cups and
said second linear array of said second plurality of cups; (c) a
first plurality of lids hinged to said first plurality of cups,
said first plurality of lids being arranged in a third linear
array, generally parallel to the medial axis between the cup
arrays, said third linear array of said first plurality of lids
being generally disposed and hinged along the sides of the first
plurality of cups opposite to the sides adjacent the medial axis
between said first linear array of said first plurality of cups and
said second linear array of said second plurality of cups; each of
said first plurality of lids being adapted to cooperate with the
means for securing it to its associated cups of the first plurality
of cups to provide sealed cup, lid assemblies upon pivotal motion
of the lid about its hinge to the upper cup aperture of its
associated cup of the first plurality of cups; and (d) a second
plurality of lids hinged to said second plurality of cups, said
second plurality of lids being arranged in a fourth linear array
generally parallel to the medial axis between the cup arrays, said
fourth linear array of said second plurality of lids being
generally disposed along the sides of the second plurality of cups
opposite to the sides adjacent the medial axis between said first
linear array of said first plurality of cups and said second linear
array of said second plurality of cups; each of said second
plurality of lids being adapted to cooperate with the means for
securing it to its associated cup of the second plurality of cups
to provide sealed cup, lid assemblies upon pivotal motion of the
lid about its hinge to the upper cup aperture of its associated cup
of the second plurality of cups, the third linear array of said
first plurality of lids and the fourth linear array of said second
plurality of lids being thus generally distally and symmetrically
disposed with respect to the medial axis between the first linear
array of the first plurality of cups and the second linear array of
the second plurality of cups.
28. The thermoformed, integral ensemble according to claim 27,
further comprising a fourth plurality of tearable portions
connecting said first plurality of lids to each other and a fifth
plurality of tearable portions connecting said second plurality of
lids to each other.
29. The thermoformed, integral ensemble according to claim 28,
wherein each of said first and second plurality of lids has a tab
portion projecting outwardly with respect to said medial axis of
the ensemble and wherein the tabs of said first plurality of lids
are linearly offset with respect to the tabs of said second
plurality of lids and configured such that the tabs of said first
and second plurality of lids will lie along the medial axis
adjacent each other when the first and second plurality of lids are
pivoted to the medial axis.
30. The thermoformed, integral ensemble according to claim 27,
wherein said sheet comprises a polystyrene polymer composition.
31. The integrally formed ensemble according to claim 30, wherein
said polystyrene polymer composition comprises high impact
polystyrene.
32. The integrally formed ensemble according to claim 30, wherein
said polystyrene polymer composition comprises rubberized
polystyrene.
33. The thermoformed, integral ensemble according to claim 30,
wherein said polystyrene polymer is oriented polystyrene.
34. The thermoformed, integral ensemble according to claim 27,
wherein said thermoplastic sheet comprises a polyolefin
polymer.
35. The thermoformed, integral ensemble according to claim 34,
wherein said polyolefin polymer is polypropylene.
36. The thermoformed, integral ensemble according to claim 34,
wherein said polyolefin polymer is polyethylene.
37. The thermoformed, integral ensemble according to claim 27,
wherein said thermoplastic sheet comprises polyethylene
terephthalate.
38. The thermoformed, integral ensemble according to claim 27,
wherein at least one of said first or second plurality of tearable
portions is scored.
39. The thermoformed, integral ensemble according to claim 27,
wherein at least one of said first or second plurality of tearable
portions is perforated.
40. The integrally formed ensemble according to claim 27, wherein
said lids are hinged to their associated cups by way of a perforate
scored hinge portion of the ensemble.
41. The thermoformed, integral ensemble according to claim 27,
prepared from thermoplastic sheet having a caliper of from about 10
to about 30 mils.
42. The thermoformed, integral ensemble according to claim 41,
prepared from thermoplastic sheet having a caliper of about 20
mils.
43. An integrally formed ensemble of interconnected separable cups
and associated lids comprising: (a) a first plurality of cups, each
of said first plurality of cups having an upper cup aperture, a cup
sidewall and a cup bottom and further including means for securing
its associated lid about its upper cup aperture; (b) means for
separably securing said first plurality of cups in a first linear
array; (c) a second plurality of cups, each of said second
plurality of cups having an upper cup aperture, a cup sidewall and
a cup bottom and including means for securing its associated lid
about its upper cup aperture; (d) means for separably securing said
second plurality of cups in a second linear array; (e) means for
separably securing said first linear array of said first plurality
of cups to said second linear array of said second plurality of
cups about a medial axis therebetween; (f) a first plurality of
lids hinged to said first plurality of cups, said first plurality
of lids being arranged in a third linear array, generally parallel
to the medial axis between the cup arrays, said third linear array
of said first plurality of lids being generally disposed and hinged
along the sides of the first plurality of cups opposite to the
sides adjacent the medial axis between said first linear array of
said first plurality of cups and said second linear array of said
second plurality of cups; each of said first plurality of lids
being adapted to cooperate with the means for securing it to its
associated cups of the first plurality of cups to provide sealed
cup, lid assemblies upon pivotal motion of the lid about its hinge
to the upper cup aperture of its associated cup of the first
plurality of cups; and (g) a second plurality of lids hinged to
said second plurality of cups, said second plurality of lids being
arranged in a fourth linear array generally parallel to the medial
axis between the cup arrays, said fourth linear array of said
second plurality of lids being generally disposed along the sides
of the second plurality of cups opposite to the sides adjacent the
medial axis between said first linear array of said first plurality
of containers and said second linear array of said second plurality
of cups; each of said second plurality of lids being adapted to
cooperate with the means for securing it to its associated
container of the second plurality of cups to provide sealed cup,
lid assemblies upon pivotal motion of the lid about its hinge to
the upper cup aperture of its associated cup of the second
plurality of containers, the third linear array of said first
plurality of lids and the fourth linear array of said second
plurality of lids being thus generally distally and symmetrically
disposed with respect to the medial axis between the first linear
array of the first plurality of cups and the second linear array of
the second plurality of cups.
44. The integrally formed ensemble according to claim 43, further
comprising means for connecting said first plurality of lids to
each other and means for connecting said second plurality of lids
to each other.
45. The integrally formed ensemble according to claim 44, wherein
each of said first and second plurality of lids has a tab portion
projecting outwardly with respect to said medial axis of the
ensemble and wherein the tabs of said first plurality of lids are
linearly offset with respect to the tabs of said second plurality
of lids and configured such that the tabs of said first and second
plurality of lids will lie along the medial axis adjacent each
other when the first and second plurality of lids are pivoted to
the medial axis.
46. The integrally formed ensemble according to claim 43,
thermoformed from thermoplastic sheet material.
47. The integrally formed ensemble according to claim 46, wherein
said thermoplastic sheet material comprises a polystyrene polymer
composition.
48. The integrally formed ensemble according to claim 47, wherein
said polystyrene polymer composition comprises high impact
polystyrene.
49. The integrally formed ensemble according to claim 47, wherein
said polystyrene polymer composition comprises rubberized
polystyrene.
50. The integrally formed ensemble according to claim 47, wherein
said polystyrene polymer is oriented polystyrene.
51. The integrally formed ensemble according to claim 46, wherein
said thermoplastic sheet material comprises a polyolefin
polymer.
52. The integrally formed ensemble according to claim 51, wherein
said polyolefin polymer is polypropylene.
53. The integrally formed ensemble according to 51, wherein said
polyolefin polymer is polyethylene.
54. The integrally formed ensemble according to claim 46, wherein
said thermoplastic sheet material comprises polyethylene
terephthalate.
55. The integrally formed ensemble according to claim 43, wherein
said first and second linear arrays of containers consist of 3
containers each and said third and fourth linear arrays of lids
consist of 3 lids each.
56. The integrally formed ensemble according to claim 43, wherein
said lids are hinged to their associated cups by way of a perforate
scored hinge portion of the ensemble.
57. An integrally formed ensemble of interconnected separable
containers and associated lids comprising: (a) a plurality of
containers arranged in an array, each container comprising a cup
and a lid adjoined thereto, the containers being separably joined
to the ensemble and each of the containers having an upper cup
aperture, a cup sidewall, and a cup bottom and further including
means for securing its associated lid about its upper cup aperture;
(b) the containers thus including a plurality of lids, each of
which is hinged to its associated cup, wherein the cups and lids
are arranged about a medial axis such that the area of the ensemble
is generally equally divided by the medial axis whereby the
ensemble is generally balanced thereabout; and (c) each of said
plurality of lids being adapted to cooperate with the means for
securing it to its associated cup upon pivotal motion of the lid
about its hinge to the upper aperture of its associated cup.
58. The integrally formed ensemble according to claim 57, wherein
said cups are arranged in a staggered linear array about the medial
axis of the ensemble.
59. The integrally formed ensemble according to claim 58, wherein
the lids are generally coplanar with the upper cup aperture of
their associated cups.
60. The integrally formed ensemble according to claim 57, wherein
the containers are separably joined by tearable portions that are
perforated.
61. The integrally formed ensemble according to claim 57, wherein
said lids are hinged to their associated cups by way of a perforate
scored hinge portion of the ensemble.
62. The integrally formed ensemble according to claim 57, wherein
the containers are separably joined by tearable portions that are
scored.
63. The integrally formed ensemble according to claim 57, wherein
each container has a fill volume of from about 1 to about 8 fluid
ounces.
64. The integrally formed ensemble according to claim 63, wherein
each container has a fill volume of from about 1 to about 4 fluid
ounces.
65. The integrally formed ensemble according to claim 64, wherein
each container has a fill volume of about 2 fluid ounces.
66. The integrally formed ensemble according to claim 57,
thermoformed from thermoplastic sheet material.
67. The integrally formed ensemble according to claim 66, wherein
said thermoplastic sheet material comprises a polystyrene polymer
composition.
68. The integrally formed ensemble according to claim 67, wherein
said polystyrene polymer composition comprises high impact
polystyrene.
69. The integrally formed ensemble according to claim 67, wherein
said polystyrene polymer composition comprises rubberized
polystyrene.
70. The integrally formed ensemble according to claim 67, wherein
said polystyrene polymer is oriented polystyrene.
71. The integrally formed ensemble according to claim 66, wherein
said thermoplastic sheet material comprises a polyolefin
polymer.
72. The integrally formed ensemble according to claim 71, wherein
said polyolefin polymer is polypropylene.
73. The integrally formed ensemble according to 71, wherein said
polyolefin polymer is polyethylene.
74. The integrally formed ensemble according to claim 66, wherein
said thermoplastic sheet material comprises polyethylene
terephthalate.
Description
CLAIM FOR PRIORITY
[0001] This non-provisional application claims the benefit of the
filing date of U.S. Provisional Patent Application Serial No.
60/389,533, of the same title, filed Jun. 18, 2002.
TECHNICAL FIELD
[0002] The present invention relates generally to disposable food
containers, and more particularly to an ensemble of sealable
containers having lids attached thereto. The containers are
connected to each other by way of tear portions.
BACKGROUND
[0003] Plastic containers such as disposable plastic containers are
well known. There is disclosed in U.S. Pat. No. 5,702,017 to
Goncalves a combination of a row of containers and a strip of caps,
each of the containers and caps being respectively joined by
breakable links allowing the joined strip of caps to be placed on
necks of the joined row of containers by a translational movement
parallel to the axes of the containers. See also U.S. Pat. No.
5,531,349 to Wojcik et al.
[0004] Disposable articles are used as food containers as is seen,
for example, in U.S. Pat. No. 5,012,971 to Cozzi et al. In the '971
patent there is disclosed a compartmented container of the "clam
shell" class suitable for containing food. The container or package
in one embodiment includes a first or bottom compartment and a
second or top compartment that is hinged to the first compartment.
There is disclosed in U.S. Pat. No. 4,798,133 to Johnson a package
and container for eggs. The container defines a plurality of
compartments each of a configuration to hold an egg captive, each
portion of the container defining a respective single compartment
being connected with the remainder along lines of weakening,
perforation or the like.
[0005] Containers arranged in arrays with breakable or tearable
portions between them are seen in a number of references.
[0006] There is disclosed in U.S. Pat. No. 6,000,535 to Berk et al.
disposable mixing wells. Wells are formed as a unitary sheet of
individual mixing wells arranged in rows and columns. The boundary
between each mixing well is scored, perforated or otherwise made to
allow individual pieces to be removed from the sheet. Preferably,
the mixing wells may be pressure formed rather than being vacuum
formed.
[0007] There is disclosed in U.S. Pat. No. 5,904,263 to St. Pierre
et al. a multi-container package with individually removable
containers. The package includes several individually sealed
containers which are easily separable from one another by weakened
zones between adjacent containers. Each container includes a tab
portion over which the peel tab of the lid extends. Dimples in
either the peel tab or tab portion facilitate their separation.
Several multi-container packages are manufactured as a unit using a
die and conventional heat sealing process and then are separated
from one another by transverse cuts.
[0008] U.S. Pat. No. 5,409,127 to Stratford et al. is directed to a
multi-pack container assembly. The multi-pack assembly includes a
plurality of containers and webs joining the containers, each web
configured to include an area of reduced structural integrity for
tearing a plurality of frangible ribs interconnecting adjacent
containers and traversing the tearing area.
[0009] U.S. Pat. No. 4,875,620 to Lane, Sr. discloses a fluted
product cup. The cup, suitable for food packaging is formed from a
resilient material and has an integral body having a product
reservoir and a lip. The product reservoir includes a flat bottom
wall and a continuous sidewall integrally joined together about a
smooth curve. The sidewall extends upwardly from the bottom wall to
join the lip. The joint between the lip and the sidewall
continuously surrounds and defines an opening through the lip to
the interior of the reservoir. The lip extends in a plane outwardly
from this opening completely around the periphery of this opening.
The bottom wall is essentially circular in shape and the opening is
essentially a square shape. First, second, third and fourth fluted
areas are located in the sidewall at the corners of the squarish
shaped opening at the top of the containers. Each of the fluted
areas are shaped essentially as a conical surface generated from a
cone which is truncated by a plane about a parabolic intersection
of the plane with the cone. These containers may be formed in an
array as can be seen in the patent.
[0010] With respect to containers which may be separated, the
following references are also of interest: French Patent No.
1,392,947 to Skandinavisk; German Patent No. DE 26 53 906 to
Gizeh-Werk and British Provisional Specification No. 649,541 to
Stephenson.
[0011] It is seen in U.S. Pat. No. 5,722,553 to Hovatter an
integral assembly of microcentrifuge strip tubes having
independently tethered caps and angularly related seal caps.
[0012] While the container art is plentiful, there remain largely
unresolved issues in the food service industry particularly with
respect to problems involved with tipping of small containers
during filling, problems associated with the loss of lids, and
problems associated with easily fitting lids onto large numbers of
containers in a short period of time as is required, for example,
in a catering operation. Small dishes (1-4 fluid ounce) are
typically used for condiments, dressing, sauces and dips in the
food service industry. By way of conventional containers when it is
desired to fill a large number of relatively small dishes, it is
necessary to lay out a large number of the individual dishes
currently used, fill each separately with the desired product while
avoiding spills between the dishes and then match up the lids with
each individual dish. Such undertaking is both tedious and
difficult with conventional containers, made all the more difficult
by small individual containers which tend to be unstable on a flat
surface and tip over and lids which may be misplaced or lost.
Moreover, large amounts of product may be lost due to difficulty in
accurately locating and aligning individual containers with the
product source. There is thus a need for an efficient disposable
food packaging system, particularly with respect to containers,
each having a cup which may conveniently and rapidly be filled and
closed with a minimum of associated equipment. Ideally, the
ensemble of containers will be configured such that, when placed on
a flat horizontal surface, the ensemble will maintain the cup
portions thereof in an upright position both before and after
filling.
SUMMARY OF INVENTION
[0013] There is provided in accordance with the present invention
an ensemble of connected containers in a separable array, each
container comprising a cup and a lid. Generally, in preferred
embodiments, the individual containers are arrayed as integrally
formed pairs which are separably connected to other pairs to make
up a separable array having an even number of containers. Each
container in the array is separably connected to at least one other
container along a medial axis and has an integrally formed lid
extending outwardly with respect to the medial axis, that is,
distally with respect to the medial axis between containers. In an
array of six containers, for example, the center most pair of
containers is joined along the medial axis and has a lid joined to
a portion of the container spaced away from the medial axis. Both
to the left and right of the centermost pair of containers are also
disposed other pairs of containers in a preferred embodiment as
will be described in detail hereinafter.
[0014] There is thus provided in accordance with the present
invention an integrally formed ensemble of interconnected separable
containers each comprising a cup and an associated lid including a
first plurality of containers arranged in a first linear array each
container in said first linear array connected to another container
in the linear array by a tearable portion of a first plurality of
tearable portions, each of said first plurality of containers
having an upper cup aperture, a cup sidewall and a cup bottom and
further including means for securing its associated lid about its
upper aperture. A second plurality of containers is disposed in a
second linear array of containers, each container in said second
linear array being connected to another by one of a second
plurality of tearable portions, each of the second plurality of
containers having an upper cup aperture, a cup sidewall and a cup
bottom and further including means for securing its associated lid
about its upper cup aperture. The first linear array of the first
plurality of containers is separably adjoined to the second linear
array of the second plurality of containers by way of a third
plurality of tearable portions arranged along a medial axis between
first linear array of the first plurality of containers and the
second linear array of the second plurality of containers.
Preferably the containers in each said array are disposed such that
the cup portions thereof are adjacent a cup portion of a container
in the other array. A first plurality of lids is hinged to the cup
portions of containers in said first plurality of containers, the
first plurality of lids being arranged in a third linear array
generally parallel to the medial axis between the container arrays
wherein the third linear array of the first plurality of lids is
generally disposed and hinged along the sides of the cup portions
of the first plurality of containers opposite to the sides adjacent
the medial axis between the first linear array of the first
plurality of containers and the second linear array of the second
plurality of containers. Each of the first plurality of lids is
adapted to cooperate with the means for securing it to its
associated cup portion of the first plurality of containers to
provide sealed cup/lid assemblies upon pivotal motion of the lid
about its hinge to the upper cup aperture of the associated
container of the first plurality of containers. A second plurality
of lids is hinged to cup portions of the second plurality of
containers, the second plurality of lids being arranged in a fourth
linear array generally parallel to the medial axis between the
container arrays wherein the fourth linear array of the second
plurality of lids is generally disposed along the sides of the cup
portions of said second plurality of containers opposite to the
sides adjacent the medial axis between the first linear array of
the first plurality of containers and the second linear array of
the second plurality of containers. Here also, each of the second
plurality of lids is adapted to cooperate with the means for
securing it to its associated cup portion of the second plurality
of containers to provide sealed cup/lid assemblies upon pivotal
motion of the lid about its hinge to the upper cup aperture of its
associated container of the second plurality of containers. The
third linear array of the first plurality of lids and the fourth
linear array of the second plurality of lids are thus generally
distally and symmetrically disposed with respect to the medial axis
between the first linear array of the first plurality of containers
and the second linear array of the second plurality of
containers.
[0015] In this manner, the integrally formed cup/lid ensemble of
the invention provides for a balanced structure which is relatively
stable on a flat surface during a filling operation. Moreover, the
associated lids are conveniently secured to their associated cups
and are readily located and secured to their associated cup
portions. Thus, the integral assembly of the present invention
solves the problems involved with tipping of small containers
during filling; problems associated with the loss of lids and
problems associated with easily fitting lids onto large numbers of
containers in a short period of time. Alternatively, a staggered
linear array of containers as shown in FIG. 11 may be employed to
provide a narrower ensemble of containers which is still balanced
for stable placement on a flat surface.
[0016] In a preferred embodiment, the lids are hinged to their
associated cups by way of a hinge that is weakened for removal. The
hinge region may be perforate scored such that the lid can be
readily removed from its associated cup. This feature is
particularly useful when it is desired to use the cup to hold a
dip, for example, wherein it is undesirable to have the lid present
during use.
[0017] Thus, in one aspect of the invention there is provided an
integrally formed ensemble of interconnected separable containers
and associated lids including: (a) a plurality of containers
arranged in an array, each container comprising a cup and a lid
adjoined thereto, the containers being separably joined to each
other and each of the containers having an upper cup aperture, a
cup sidewall, and a cup bottom and further including means for
securing its associated lid about its upper cup aperture; (b) the
containers thus including a plurality of lids, each of which is
hinged to its associated cup, wherein the cups and lids are
arranged about a medial axis such that the area of the ensemble is
generally equally divided by the medial axis whereby the ensemble
is generally balanced thereabout; and (c) each of the plurality of
lids being adapted to cooperate with the means for securing it to
its associated cup upon pivotal motion of the lid about its hinge
to the upper aperture of its associated cup. Typically, the cups
are arranged in a staggered linear array about the medial axis of
the ensemble and the lids are generally coplanar with the upper cup
aperture of their associated cups.
[0018] A particularly preferred embodiment is an ensemble of
containers where two container arrays each having three cups and
two arrays of lids each having three lids. The tearable portions
between containers are typically thermoformed from the same sheet
material as the cups and lids and may form continuous strips
therebetween which intersect other continuous strips between
containers as shown in the drawings. Other means for connecting the
containers to each other may be employed, such as discrete
projections or "tabs" of material between containers if so desired.
Typically the tearable portions between containers will be
perforated or scored to make it easier to separate single
containers from other containers in the array or ensemble of
containers.
BRIEF DESCRIPTION OF DRAWINGS
[0019] The invention is described in detail below with reference to
the various figures in which like numbers designate similar parts
and wherein:
[0020] FIG. 1 is a schematic view in perspective of a 2.times.3
configuration of a container and lid ensemble of the present
invention;
[0021] FIG. 2 is an end view in elevation of the ensemble of the
container/lid ensemble of FIG. 1 generally along line 2-2 of FIG.
1;
[0022] FIG. 3 is a side view in elevation of the container/lid
ensemble of FIG. 1 generally along line 3-3 of FIG. 1;
[0023] FIG. 4 is a perspective view in partial section of the
container/lid ensemble of FIG. 1 along line 4-4 of FIG. 1 showing
the various features;
[0024] FIG. 5 is a view in elevation and section along line 4-4 of
FIG. 1;
[0025] FIG. 6 is an enlarged schematic view showing a lid joined
with its associated container;
[0026] FIG. 7 is an enlarged schematic view showing two containers
separably joined about the medial axis of the ensemble;
[0027] FIG. 8 is an enlarged partial top perspective view of the
container ensemble of FIG. 1 along its medial axis showing the lids
secured to their associated containers;
[0028] FIG. 9 is an enlarged schematic view of a container/lid
combination wherein the lid has been pivoted to the medial axis to
seal the container; and
[0029] FIG. 10 is a schematic view in perspective showing a
container/lid ensemble of the present invention wherein 24
container/lid combinations are shown in one embodiment of the
present invention integrally formed in a sheet;
[0030] FIG. 11 is a schematic view in perspective showing a
container/lid ensemble of the present invention wherein 6
container/lid combinations are shown in one embodiment of the
present invention integrally formed in a sheet wherein the
containers are arranged in a staggered configuration;
[0031] FIG. 12 is a plan view of another 2.times.3 configuration of
a container and lid ensemble of the present invention; and
[0032] FIG. 13 is a plan view of still yet another 2.times.3
configuration of a container and lid ensemble of the present
invention
DETAILED DESCRIPTION
[0033] The invention is described in detail below in connection
with various embodiments of the present invention. Such description
and exemplification is for purposes of illustration only.
Modifications to those embodiments within the spirit and scope of
the present invention, set forth in the appended claims, will be
readily apparent to those of skill in the art.
[0034] The integrally formed, container/lid arrays of the present
invention may be conveniently formed by way of any conventional
molding technique from a plastic material such as by a
thermoforming process from a suitable thermoplastic sheet.
"Thermoforming", "thermoformed" and like terminology is given its
ordinary meaning. In the simplest form, thermoforming is the
draping of a softened sheet over a shaped mold. In the more
advanced form, thermoforming is the automatic high speed
positioning of a sheet having an accurately controlled temperature
into a pneumatically actuated forming station whereby the article's
shape is defined by the mold, followed by trimming and regrind
collection as is well known in the art. Still other alternative
arrangements include the use of drape, vacuum, pressure, free
blowing, matched die, billow drape, vacuum snap-back, billow
vacuum, plug assist vacuum, reverse draw with plug assist, pressure
bubble immersion, trapped sheet, slip, diaphragm, twin-sheet cut
sheet, twin-sheet roll-fed forming or any suitable combinations of
the above. Details are provided in J. L. Throne's book,
Thermoforming, published in 1987 by Coulthard. Pages 21 through 29
of that book are incorporated herein by reference. Suitable
alternate arrangements also include a pillow forming technique
which creates a positive air pressure between two heat softened
sheets to inflate them against a clamped male/female mold system to
produce a hollow product. Metal molds are etched with patterns
ranging from fine to coarse in order to simulate a natural or grain
like texturized look. Suitable formed articles are trimmed in line
with a cutting die and regrind is optionally reused since the
material is thermoplastic in nature. Other arrangements for
productivity enhancements include the simultaneous forming of
multiple articles with multiple dies in order to maximize
throughput and minimize scrap. In some preferred embodiments, the
melt-compounded composition from which the articles are made may
include polypropylene and optionally further includes a
polyethylene component and titanium dioxide. Suitable materials and
techniques for fabricating the disposable containers of the present
invention from thermoplastic materials appear in U.S. Pat. No.
6,211,501 to McCarthy et al. as well as U.S. Pat. No. 6,211,500 to
Cochran II et al. the disclosures of which are incorporated herein
by reference.
[0035] Alternatively, the lid/container ensemble may be injection
molded; however, thermoforming is generally preferred.
[0036] When a container in the ensemble is joined to another
container in the array, the interconnecting joining portion is
formed to incorporate a line of weakness, whether by scoring,
perforating, or merely forming the array in such a fashion that the
polymer is considerably thinner along the joining portion so that
after containers in the array are filled and lidded, a single
container in the array may be easily separated by a simple tearing
motion. It is preferred that the mouth or upper apertures of the
containers substantially fill the plane containing the medial axis
between the container arrays so that problems of spills between
containers are substantially obviated. It is also preferred that
the integrally formed lids are attached to each other and are
separably joined to adjacent lids in a similar fashion so that the
array may be easily filled, lidded and then separated after the lid
has been engaged with the mouth of the container. For purposes of
balance, it is preferred that the lids in essence balance each
other by being arrayed on opposite sides of the medial axis between
the linear arrays of containers.
[0037] A preferred shape for the mouth of each separable container
is generally rectangular, and it is likewise preferred that the
lower portion of the container is generally rectangular. A typical
container will have a flat or slightly upwardly convex bottom so
that the container will remain in a stable position when placed on
a flat surface such as a table. Extending peripherally around the
generally rectangular mouth of the container is a land area
adjoining a downwardly extending rim or ridge connected to a
generally planar surround portion extending between each container.
A joining portion between the surrounds of the containers
preferably has a line of weakness whether formed by scoring,
perforations, thinning or other known technique of forming a line
of weakness in polymer materials. Surrounds of the containers in
the array have at least two regions, a medial region along the
medial axis between the arrays of containers and a distal region on
the side of the containers opposite their medial regions. The
distal region adjoins a hinge region by way of which lids are
extending outwardly with respect to the containers. The lids have a
groove with any convenient profile dimensioned to cooperate with a
ridge having a mating profile about the upper cup apertures of the
containers as will be described in more detail below with reference
to the various figures. Preferably the lids include a molded-in
area defining a recess facilitating stacking and handling of
numerous arrays of container/lid ensembles as will be appreciated
from the discussion which follows.
[0038] The hinges are preferably joined to their associated
containers by a hinge area which is likewise formed to incorporate
a line of weakness, whether by scoring, perforating or merely
forming the array in such a fashion that the polymer is
considerably thinner in selected areas so that the lid may be
separated if so desired. As noted above, this feature is desirable
when the cup is used as a serving container for a dip, for
example.
[0039] Referring generally, to FIGS. 1 through 9, there is shown an
integrally formed, container/lid ensemble 10 in a 2.times.3
configuration. The ensemble 10 includes a plurality of first
containers 12, 14 and 16 arranged in a first linear array 17 and
joined to one another by a plurality of tear portions 18 and 20.
Each container includes an upper aperture 24, 26 and 28 as shown in
the figures as well as sidewalls 30, 32 and 34. The containers also
have bottoms 36, 38 and 40 as well as ridges 42, 44, and 46 about
their upper apertures. Ridges 42, 44 and,46 generally have a
rectangular profile as shown at 48, 50 and 52 for ease of
thermoforming. Tear portions 18, 20 as well as those tear portions
referred to below may be formed in a continuous surround about the
peripheries of the containers and lids as can be seen in the
Figures.
[0040] There is further provided a second linear array 59 of
containers 54, 56 and 58 which are connected to each other by tear
portions 60 and 62. The containers likewise have upper apertures or
mouths 66, 68 and 70 as well as sidewalls 72, 74, and 76; bottoms
78, 80 and 82; and upper ridges 84, 86 and 88 about their
apertures. The ridges about the second linear array of containers
also have rectangular profiles as indicated at 90, 92 and 94.
[0041] A plurality of tear portions 96, 98 and 100 connect first
linear array of containers 17 to second linear array of containers
59 along a medial or interior axis 102 as is shown in FIG. 1.
[0042] There is disposed on the side of container array 17 distal
to medial axis 102 a set of lids 104 also arranged in a linear
array 105. Array 105 includes lid 106, lid 108 and lid 110 which
are respectively connected by way of tear portions 112 and 114.
Each lid further includes a groove 118, 120 and 122. Each groove
respectively defines a rectangular profile 124, 126 and 128 which
will be further appreciated by way of reference to FIG. 9 discussed
below. Array 105 is hinged to the container array 17 by way of a
hinge 130.
[0043] There is further provided another set of lids 132 along the
side of container array 59 distal to medial axis 102 on the other
side of the ensemble that is the side opposite lid array 105. An
array of lids 133 includes a lid 134, a lid 136, as well as a lid
138. The lids are joined by tearable portions 140 and 142. Here
again the lids are provided with grooves 146, 148 and 150 each of
which have a rectangular profile 152, 154 and 156 as shown in the
various Figures. These lids are also attached by way of another
hinge 144.
[0044] The container/lid ensemble of the present invention is
conveniently fabricated by thermoforming as noted above. In
preferred methods of thermoforming a plug assist may be employed as
is well known in the art. The ensemble when formed has a generally
planar upper surface as can be seen particularly in FIGS. 1 and 2
and typically includes a plurality of tab portions associated with
the lids as is best seen in FIGS. 1, 4 and 12 (discussed
hereinafter). Each lid 106, 108, 110, 134, 136 and 138 has at its
periphery a tab 158, 160, 162, 164, 166 and 168. As will be
appreciated from FIG. 1 and FIG. 8 the tabs are axial or linearly
offset with the tab on the lid directly opposed across medial axis
102. That is to say tab 158 of lid 106 is at the outer most corner
of the lid near its adjacent lid 108 whereas tab 164 of lid 134 is
at the corner of lid 134 away from lid 136. When the lids are
folded over inwardly to their closed position as is shown in FIG. 8
the tabs lie adjacent each other generally along axis 102, and do
not overlap so that the containers can be sealed and provided with
a tab to facilitate opening. It is further noted that the tab
projects outwardly or past the medial axis 102 which is generally
coincident with the various tear portions between the
containers.
[0045] There may optionally be provided a plurality of raised dots,
such as raised dots 161, 163 located to underlie the lids in the
sealing position as is known in the art to facilitate opening of
the containers.
[0046] Containers of the invention may be made of any suitable
polymer. A class of polymers frequently employed for this type of
container includes polystyrene polymers which consist predominantly
of styrenic monomer units and may include, for example, butadiene
co-monomers. Particularly preferred polymeric materials for making
the inventive containers include high impact polystyrene (HIPS) and
rubberized polystyrene. Oriented polystyrene sheet may also be
employed. Another class of polymers from which the inventive
container/lid ensemble may be made include polyolefin polymers such
as polypropylene and polyethylene. Likewise polyesters are
suitable, particularly polyethylene terephthalate polymers often
referred to in the art as "bottle resin".
[0047] It will be appreciated from the various Figures that the
upper apertures of the containers such as apertures 24, 26 and
bottoms 36, 38 are generally rectangular. Preferably, the
rectangular portions of the sidewalls are interconnected by arcuate
portions to facilitate removal of the contents of the
containers.
[0048] The lids have a plurality of molded-in regions, 182, 184,
186, 188, 190 and 192 formed therein which have on their opposite
side recesses corresponding to the generally rectangular bottoms of
the containers for enhancing stacking. That is to say the molded-in
regions 184, 190 shown in FIG. 1 form recesses such as recesses 194
and 196 shown on FIG. 8 for receiving the bottoms of another stack
of containers and lids as will be appreciated from the diagram. The
lids are provided with grooves having a convenient profile such as
profile 154 shown schematically and enlarged in FIG. 9 where the
profile 154 cooperates with the mating profile 92 of ridge 86 in
order to provide for a liquid resistant seal. That is to say in
FIG. 9 the lids have been folded over as shown in FIG. 8 and the
grooves engaged to the ridges around the periphery of the
containers to provide for a seal. In preferred embodiments, the
ridge and groove will have undercut mating portions to further
facilitate a secure leak resistant seal when the lid is secured
over the cup portion of each container. Provided in the interior of
the containers is a stacking ledge such as stacking ledges 198 and
200 shown in FIG. 7 which are provided with a uniform width (D)
around the entire periphery of the interior of the container. The
apertures of the containers generally have a width (W) of about one
to three inches and a length (L) of about one to three inches. So
also, the depth or height of the container (H) FIG. 2, is typically
from about 1 to about 3 inches such that the fill volume of the
container is preferably from about 1 to about 8 fluid ounces. A
fill volume of about 2 fluid ounces is typical. As noted above, to
make the containers easily separable from each other container in
the ensemble, the weakened zones between containers and lids may be
perforated or scored to make them easily tearable as shown
schematically at 202, 204 and 206 in the various diagrams.
[0049] Typically the container/lid assembly of the present
invention is thermoformed from a thermoplastic sheet having a
thickness or caliper of from about 10 to about 30 mils (thousandths
of an inch). A thermoplastic sheet having a caliper of about 20
mils is typical.
[0050] There is further shown in FIG. 10 an embodiment of the
present invention wherein multiple sets of containers and lids have
been thermoformed in a single mold. In the embodiment of FIG. 10
shows 24 containers and their associated lids generally having the
structure shown in FIGS. 1 through 9. For purposes of convenience,
the various features are labeled 200 numerals higher for purposes
of brevity. It can be seen in FIG. 10 that the various arrays of
containers 217, 259 are separated by a medial axis 302 and hinged
to arrays of lids 305 and 333. The substructure or unit structure
illustrated is repeated throughout the sheet such that multiple
arrays may be formed in a single operation as will be appreciated
by one of skill in the art.
[0051] In FIG. 11, yet another embodiment is shown wherein a
container ensemble 350 includes a plurality of cups 352, 354, 356,
358, 360 and 362 adjoined to the ensemble by scored or perforated
tearable portions indicated generally at 364, 366, 368, 370 and
372. The cups are arranged about a medial axis 374 in a staggered
array 376. Here, it is seen that the projected surface area of the
ensemble is generally symmetrical about axis 374 so that the
ensemble is generally balanced; that is, lids 378, 380, 382, 384,
386 and 388 have generally the same area as their corresponding cup
on the opposite side of medial axis 374.
[0052] Still yet another embodiment of the present invention is
shown in FIG. 12 which is a plan view of a 2.times.3 container/lid
ensemble 400 including cups 402, 404, 406, 408, 410 and 412 as well
as their associated lids 414, 416, 418, 420, 422 and 424. Cups 402,
404 and 406 form a first linear array 426 while cups 408, 410 and
412 form a second linear array 428 of cups as shown. The cups are
arranged along opposite sides medial axis 430 which generally
divides the ensemble.
[0053] The upper aperture of each cup includes a surround portion
such as portions 432, 434 and so forth that are provided with a
plurality of arcuate ridges such as ridges 436, 438, 440 and 442
which project upwardly from surround portions 432, 434. The ridges
are arranged generally along the medial axis and are configured to
project outwardly with respect to a cup's associated lid when the
container is closed. The ridges are also positioned away from
adjacent cups so that they can operate to provide a grip when
needed, such as when separating a container from the rest of the
ensemble as well as to aid in opening a sealed container. If so
desired, the ridges can also be configured to provide raised areas
to that the lid will overlap them when closed to provide some
separation between the surrounds of the lids and cups.
[0054] In the embodiment of FIG. 12, there are provided open areas
444, 446, 448, 450, 452 and 454 in the upper surface of the
ensemble. Lids 414-424 are hinged to their associated containers
402-412 by way of perforate hinge portions 456, 458, 460, 462, 464
and 466 of the integrally formed ensemble 400 so that the lids may
be readily separated if so desired. Likewise, the lids and cups are
separably joined to others by way of perforate portions 468, 470,
472, 474, 476, 478, 480 and 482.
[0055] In the embodiment of FIG. 13, lids 514-524 are hinged to
their associated containers 502-512 by way of perforate hinge
portions 556, 558, 560, 562, 564 and 566 of the integrally formed
ensemble 500 so that the lids may be readily separated if so
desired. Likewise, the lids and cups are separably joined to others
by way of perforate portions 568, 570, 572, 574, 576, 578, 580 and
582, as well as perforate portions 585 and 587. Note that the
containers have outwardly protruding corner sections as are seen at
584, 586, and the lids have tabs such as tab 588 which will project
beyond angled rim 590 when the lids are folded over.
[0056] While the invention has been described in detail in
connection with several embodiments, modifications within the
spirit and scope of the invention, set forth in the appended
claims, will be readily apparent to those of skill in the art.
* * * * *