U.S. patent application number 10/751786 was filed with the patent office on 2004-08-26 for lidded container with linear brim segments and medial sealing beads.
Invention is credited to Baker, Loren G., Handel, Gerald J. Van, Rush, Jonathan E., Whitmore, Rebecca E..
Application Number | 20040164076 10/751786 |
Document ID | / |
Family ID | 34794686 |
Filed Date | 2004-08-26 |
United States Patent
Application |
20040164076 |
Kind Code |
A1 |
Baker, Loren G. ; et
al. |
August 26, 2004 |
Lidded container with linear brim segments and medial sealing
beads
Abstract
An improved lidded container includes a receptacle portion with
a brim having a plurality of lateral substantially straight brim
wall segments provided with medial sealing beads extending between
corners of the brim. The medial sealing beads are characterized in
that they project away from the respective walls upon which they
are disposed a maximum distance at a central portion of the wall
and the medial sealing beads extend over a major portion of the
length of the lateral sealing wall upon which they are disposed.
Most preferably, the beads are tangent with and terminate at
rounded corners between the wall segments.
Inventors: |
Baker, Loren G.;
(Saylorsburg, PA) ; Rush, Jonathan E.; (Easton,
PA) ; 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: |
34794686 |
Appl. No.: |
10/751786 |
Filed: |
January 5, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10751786 |
Jan 5, 2004 |
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10456207 |
Jun 6, 2003 |
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60389533 |
Jun 18, 2002 |
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Current U.S.
Class: |
220/23.4 ;
220/839 |
Current CPC
Class: |
B65D 2543/00509
20130101; B65D 2543/00537 20130101; B65D 2543/00194 20130101; B65D
2543/00953 20130101; B65D 1/30 20130101; B65D 2543/00842 20130101;
B65D 2543/00555 20130101; B65D 43/162 20130101 |
Class at
Publication: |
220/023.4 ;
220/839 |
International
Class: |
B65D 021/02; B65D
051/04 |
Claims
What is claimed is:
1. In a lidded container including a receptacle portion with a brim
provided with a plurality of lateral, substantially straight brim
wall segments extending between a plurality of corners which link
the brim lateral wall segments and a lid adapted to engage the
brim, wherein the lid likewise includes a plurality of lateral,
substantially straight lid wall segments extending between a
plurality of lid corners, the improvement comprising a plurality of
medial sealing beads disposed on the substantially straight lateral
brim wall segments or the substantially straight lateral lid wall
segments, the medial sealing beads being characterized in that: (i)
the medial sealing beads project away from their respective walls a
maximum distance at a central portion thereof between and distal to
adjacent corners with lesser projections away from their lateral
walls at their end portions proximate to the corners; and (ii) the
medial sealing beads extend over the major portion of the length of
the lateral wall segment upon which they are disposed.
2. The improvement according to claim 1, wherein the medial sealing
beads terminate at or prior to the corners at either end of the
wall segment.
3. The improvement according to claim 1, wherein the brim of the
receptacle portion is U-shaped and the lid is provided with a
corresponding U-shaped channel.
4. The improvement according to claim 1, wherein the plurality of
medial sealing beads extends over substantially the entire distance
between adjacent rounded corners.
5. The improvement according to claim 1, wherein the plurality of
medial sealing beads defines an arched line between adjacent
rounded corners.
6. The improvement according to claim 1, wherein the medial sealing
beads blend with the rounded corners at end portions of the medial
sealing beads.
7. The improvement according to claim 1, wherein the medial sealing
beads are tangent with adjacent rounded corners at their end
portions.
8. The improvement according to claim 1, wherein the medial sealing
beads have an arched profile away from the lateral walls upon which
they are disposed.
9. A lidded container comprising: (a) a receptacle portion having
(i) a bottom; (ii) a side wall defining; (iii) an upper aperture;
(b) the receptacle portion being further provided with a brim
extending around the upper aperture, the brim including: (i) a
plurality of rounded corner brim portions; and (ii) a plurality of
lateral brim walls extending between the rounded brim corner
portions, the walls being configured such that the surfaces are
substantially linear along a direction between adjacent brim
corners interconnected thereby; (c) a lid adapted to engage the
brim and together with the receptacle portion and brim define a
sealed container, the lid being suitably provided with: (i) a
plurality of lid rounded corner portions; and (ii) a plurality of
lateral lid walls extending between the rounded corner portions
wherein the lid rounded corner portions and the lid lateral walls
are configured to engage corresponding brim corner portions and the
lateral brim walls thereof, the lateral lid walls being configured
such that their surfaces are substantially linear between adjacent
lid corner portions interconnected thereby; and (d) a plurality of
medial sealing beads disposed on lateral walls selected from
lateral brim walls and lateral lid walls, the sealing beads being
characterized in that: (i) the medial sealing beads project away
from their respective lateral walls a maximum distance at a central
portion thereof between and distal to adjacent corners with lesser
projections away from their lateral walls at their end portions
proximate adjacent corners; and (ii) the medial sealing beads
extend over the major portion of the length of the lateral wall
between adjacent corners upon which they are disposed.
10. The lidded container according to claim 9, thermoformed from a
thermoplastic material.
11. The lidded container according to claim 9, made from a
thermoplastic composition comprising a polystyrene polymer
composition.
12. The lidded container according to claim 11, wherein the
polystyrene polymer composition comprises high impact
polystyrene.
13. The lidded container according to claim 11, wherein the
polystyrene polymer composition comprises rubberized
polystyrene.
14. The lidded container according to claim 11, wherein the
polystyrene polymer composition is oriented polystyrene.
15. The lidded container according to claim 9, made from a
thermoplastic composition comprising a polyolefin polymer.
16. The lidded container according to claim 15, wherein the
polyolefin polymer is polypropylene.
17. The lidded container according to claim 15, wherein the
polyolefin polymer is polyethylene.
18. The lidded container according to claim 9, made from a
thermoplastic composition comprising polyethylene
terephthalate.
19. The lidded container according to claim 9, made by way of
injection molding.
20. The lidded container according to claim 9, wherein the
container has a fill volume of from about 1 to about 8 fluid
ounces.
21. The lidded container according to claim 20, wherein the
container has a fill volume of from about 1 to about 4 fluid
ounces.
22. The lidded container according to claim 20, wherein the
container has a fill volume of about 2 fluid ounces.
23. The lidded container according to claim 9, wherein the brim is
U-shaped and the lid is provided with a corresponding U-shaped
channel.
24. The lidded container according to claim 9, wherein the
plurality of medial sealing beads extends over substantially the
entire distance between rounded corners.
25. The lidded container according to claim 9, wherein the
plurality of medial sealing beads defines an arched line between
adjacent rounded corners.
26. The lidded container according to claim 9, wherein the medial
sealing beads blend with the rounded corners at ends of the medial
sealing beads.
27. The lidded container according to claim 9, wherein the medial
sealing beads are tangent with rounded corners at their end
portions.
28. The lidded container according to claim 9, wherein the medial
sealing beads have an arched profile away from the lateral walls
upon which they are disposed.
29. The lidded container according to claim 9, wherein the lateral
walls upon which the sealing beads are disposed have an upper
portion and lower portion and the medial sealing beads are located
proximate to the upper portions of the lateral walls upon which
they are disposed.
30. The lidded container according to claim 29, wherein the lateral
walls upon which the medial sealing beads are disposed have a top
and bottom defining a height and the medial sealing beads are
disposed at the upper portion of its lateral wall at substantially
two-thirds the height of the lateral wall.
31. The lidded container according to claim 9, wherein the medial
sealing beads have a maximum projection away from the lateral wall
at substantially the center line of the lateral wall.
32. A thermoformed disposable lidded container comprising: (a) a
substantially rectangular receptacle portion with: (i) a bottom;
and (ii) a sidewall defining; (iii) an upper aperture; (b) the
receptacle portion being further provided with a generally
rectangular brim extending around the upper aperture, the brim
including; (i) a U-shaped profile portion defining; (ii) a
plurality of rounded corner brim portions; and (iii) a plurality of
outer lateral brim walls extending between the rounded brim corner
portions, the outer brim walls being configured such that their
surfaces are substantially linear along the direction between
adjacent brim corner portions interconnected thereby; (c) a lid
having: (i) a rectangular sealing channel with rounded corners
adapted to fit over the brim thereby forming a sealed container
with the receptacle portion; (d) wherein outer lateral brim walls
are provided with a plurality of medial sealing beads characterized
in that: (i) the medial sealing beads project away from the
respective outer lateral brim walls a maximum distance at a central
portion thereof between and distal to the corners with lesser
projections away from the outer lateral brim wall at its end
portions proximate to the corners; and (ii) the medial sealing
beads extend over the major portion of the length of the outer
lateral brim walls upon which it is disposed between adjacent
corners.
33. The lidded container according to claim 32, wherein each outer
lateral brim wall is provided with a medial sealing bead
characterized in that: (i) the medial sealing beads project away
from the respective outer lateral brim walls a maximum distance at
a central portion thereof between and distal to the corners, with
lesser projections away from the outer lateral brim wall at its end
portions proximate to the corners; and (ii) the medial sealing
beads extend over the major portion of the length of the outer
lateral brim wall upon which it is disposed between adjacent
corners.
34. The lidded container according to claim 32, wherein the lid is
hinged to the receptacle.
35. The lidded container according to claim 32, wherein the outer
lateral walls of the brim have a substantially planar surface.
36. 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 hingedly adjoined thereto, the containers being separably
joined to the ensemble and each of the containers having an upper
cup aperture, a cup sidewall and cup bottom and further including a
generally rectangular cup brim about its upper cup aperture
including four lateral sealing walls interconnected by four rounded
corners; (b) the containers thus including a plurality of lids each
of which is hinged to its associated cup; (c) each of said
plurality of lids being adapted to cooperate with the sealing walls
of its associated cup brim upon pivotable motion of the lid about
its hinge to form a sealed container wherein the lateral sealing
walls of the brim are each provided with a medial sealing bead
characterized in that: (i) the medial sealing beads project away
from the respective outer lateral brim walls a maximum distance at
central portions thereof between and distal to the corners, with
lesser projections away from the outer lateral brim walls at their
end portions proximate to the corners; and (ii) the medial sealing
beads extend over the major portion of the length of the outer
lateral brim wall upon which it is disposed between adjacent
corners.
37. The integrally formed ensemble according to claim 36, wherein
the lids are generally co-planar with the upper cup aperture of
their associated cups.
38. The integrally formed ensemble according to claim 36, wherein
the containers are separably joined by tearable portions that are
perforated.
39. The integrally formed ensemble according to claim 36, wherein
the lids are hinged to the associated cups by way of perforate
scored hinged portions of the ensemble.
40. The integrally formed ensemble according to claim 36, wherein
the containers are separately joined by tearable portions that are
scored.
41. The integrally formed ensemble according to claim 36, wherein
each container has a fill volume of from about 1 to about 8 fluid
ounces.
42. The integrally formed ensemble according to claim 36, wherein
each container has a fill volume of from about 1 to about 4 fluid
ounces.
43. The integrally formed ensemble according to claim 36, wherein
each container has a fill volume of about 2 fluid ounces.
44. The integrally formed ensemble according to claim 36, wherein
each lid has a generally planar configuration.
45. 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 hingedly 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 a generally rectangular cup brim with
four lateral sealing walls interconnected by four rounded corners
wherein the lateral sealing walls of the cup brim are each provided
with a medial sealing bead characterized in that: (i) the medial
sealing beads project away from the respective outer lateral brim
walls a maximum distance at a central portion thereof between and
distal to the corners, with lesser projection away from the outer
lateral brim wall at their end portions proximate to the corners;
and (ii) the medial sealing beads extend over the major portion of
the length of the outer lateral brim wall upon which it is disposed
between adjacent corners; (b) a second plurality of containers
arranged in a second linear array each container comprising a cup
and a lid hingedly 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 further
including a generally rectangular cup brim with four lateral
sealing walls interconnected by four rounded corners wherein the
lateral sealing walls of the cup brim are each provided with a
medial sealing bead characterized in that: (i) the medial sealing
beads project away from the respective outer lateral brim walls a
maximum distance at a central portion thereof between and distal to
the corners, with lesser projections away from the outer lateral
brim wall at its end portions proximate to the corners; and (ii)
the medial sealing beads extend over the major portion of the
length of the outer lateral brim wall upon which they are disposed
between adjacent corners; (c) wherein said first linear array of
said first plurality of containers is secured to the second linear
array of said second plurality of containers by 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; (d) there thus
being 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, said first plurality of lids being
adapted to cooperate with the sealing walls of the associated cup
brim of the first plurality of containers to provide sealed cup,
lid assemblies upon pivotable motion of the lid about its hinge and
securing the lid to its associated cup brim of the first plurality
of containers; and (e) 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 side adjacent the medial axis between
said first linear array of said first plurality of containers and
the second linear array of said second plurality of containers;
each of said second plurality of lids being adapted to cooperate
with the sealing walls of its associated cup brim of the second
plurality of containers to provide sealed cup, lid assemblies upon
pivotable motion of the lid about its hinge and securing the lid to
its associated cup brim 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 said first plurality of
containers and a second array of said second plurality of
containers.
Description
CLAIM FOR PRIORITY
[0001] This non-provisional application is a continuation-in-part
of U.S. patent application Ser. No. 10/456,207 entitled "Separable
Containers Arranged in Arrays With Integrally Formed Lids", filed
on Jun. 6, 2003, the priority of which is claimed. This application
also claims the benefit of the filing date of U.S. Provisional
Patent Application Serial No. 60/389,533, filed Jun. 18, 2002.
BACKGROUND
[0002] Plastic containers with lids 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.; French patents 2 763 314 of APRI
and 1 278 149 of GOIFFON.
[0003] 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.
[0004] Containers arranged in arrays with breakable or tearable
portions between them are seen in a number of references. In this
respect, German Patent DE 100 12 364 of von der Worth discloses
separable egg cartons arranged in a planar array.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] Food containers having sealing features are likewise well
known. In this respect, ridges and cooperating grooves are used in
many such containers. See U.S. Pat. No. 5,377,860 to Littlejohn et
al. The above applications, publications and patents are
incorporated herein by reference.
[0012] While the container art is plentiful, there remain largely
unresolved issues with respect to lidded containers of low cost
that can exhibit superior sealing characteristics, even at low
product weight. This is especially so with respect to containers
having straight brim segments. Simply making a "tighter" fit
between the lid and its associated container or receptacle is
ineffective since the increase in the required capping force will
crush the container, leading to product failure in too many
instances as well as associated spillage.
SUMMARY OF INVENTION
[0013] There is provided in accordance with a first aspect of the
present invention a lidded container including a receptacle portion
with a brim having a plurality of lateral, substantially straight
brim lateral wall segments extending between corners, which corners
link the brim lateral wall segments; a lid adapted to engage the
brim is included, wherein the lid likewise includes a plurality of
lateral, substantially straight lid wall segments extending between
lid corners. The improvement of the present invention provides a
plurality of medial sealing beads disposed on the substantially
straight lateral brim wall segments or the substantially straight
lateral lid wall segments, the medial sealing beads being
characterized in that (i) the medial sealing beads project away
from their respective walls a maximum distance at a central portion
thereof between and distal to the corners with lesser projections
away from their lateral walls at their portions proximate to the
corners and (ii) the medial sealing beads extend over the major
portion of the length of the lateral wall segment upon which they
are disposed. Preferably, the beads terminate at or prior to the
corners at either end of the wall segment. By "major portion" it is
meant that the sealing beads extend over more than 50% of the
length of the straight wall segment. The unique geometry of the
present invention provides enhanced sealing, yet does not
substantially increase the cap force required to close the
container, such that it is especially useful for thermoformed,
disposable containers.
[0014] There is thus provided in a preferred embodiment the
addition of a male bead along the straight side of a square (with
round corners) souffl container (hereinafter referred to as the
cup) brim. This product may be produced in a six-pack design as is
shown herein to be separated by the end user. A six-pack design is
especially suitable for 2-ounce containers, while the inventive
product may likewise be produced in a four-pack design which is
especially suitable for 4 -ounce containers. The lid bead seal
improvement achieved by way of the medial sealing bead is not
limited to these configurations. The lid bead seal can be employed
in connection with a wide variety of containers as described and
claimed herein. The invention is perhaps most preferably
incorporated into a bead of semi-circular cross section or profile
as is shown in FIG. 4 approximately one third the distance down
from the top of the brim when viewed from the top of the cup. The
bead is at its fullest protrusion or projection at the center line
of the straight side of the cup and runs tangent to the corner
radii on either side. The height of the bead is most preferably
0.008 inches in the embodiments tested, progressively diminishing
or feathering out to 0.000 at a tangency of the corner radius. That
is to say, the highest point of the 0.008 arc attains a crown on
the center line of the cup when viewed from the top and tapers to
the tangent point of the corner on both ends of the arc as is best
appreciated from FIG. 3. Without intending to be bound by any
theory, it is believed that the cup bead feature performs the
sealing function because it increases pressure between the lid and
cup brim when it is normally at its lowest; that is, in the center
of the flat sides. The flat sides of the square cup or container
are difficult to seal due to the lack of pressure or contact along
the flat side of the brim. Simply reducing the size of the lids
distorts the cup and causes the brim to buckle and makes capping
difficult. Because the bead provides a point of contact and exerts
pressure exactly where it is needed, leak resistance is greatly
improved with minimal increase of capping force. The bead also acts
as a strengthening rib to prevent buckling of the brim. The test
data hereinafter included of improved leak resistance is in fact
dramatically achieved without increasing the capping force required
to seal the container.
[0015] In another aspect of the present invention, there is
provided a lidded container including a receptacle portion having
(i) a bottom portion and (ii) a sidewall portion defining (iii) an
upper aperture. The receptacle portion is further provided with a
brim extending around the upper aperture the brim including (i) a
plurality of rounded corner brim portions and (ii) a plurality of
lateral brim walls extending between the rounded brim corner
portions, the walls being configured such that their surfaces are
substantially linear along a direction between adjacent brim
corners interconnected thereby. A lid is adapted to engage the brim
and together with the receptacle portion and its brim define a
sealed container, the lid is suitably provided with (i) a plurality
of lid rounded corner portions and (ii) a plurality of lateral lid
walls extending between lid rounded corner portions wherein the lid
rounded corner portions and the lateral lid walls are configured to
engage the corresponding brim corner portions and lateral brim
walls, the lateral lid walls likewise being configured such that
their surfaces are substantially linear between adjacent lid corner
portions interconnected thereby. There is further provided a
plurality of medial sealing beads disposed on lateral walls
selected from the lateral brim walls and the lateral lid walls, the
medial sealing beads being characterized as noted above.
[0016] Most preferably, the lidded container according to the
present invention is thermoformed from a plastic material. Such
materials may include polystyrene polymer compositions, such as
high impact polystyrenes or rubberized polystyrene. Further
polystyrenes contemplated for use in connection with the present
invention include oriented polystyrene. Alternatively, the
inventive containers maybe made from a thermoplastic composition
including a polyolefin polymer such as polypropylene or
polyethylene. Still further suitable materials include polyester
materials such as a thermoplastic composition including
polyethylene terephthalate.
[0017] Instead of being made by way of thermoforming, the inventive
containers may be made by injection molding if so desired.
Typically, in a preferred embodiment, the container has a fill
volume of from about 1 to about 8 fluid ounces, such as from about
1 to about 4 fluid ounces. In the embodiments specifically
illustrated hereinafter, the containers have a fill volume of about
2 fluid ounces and are particularly useful for condiments.
[0018] The lidded containers may include a U-shaped rim on the
receptacle and a corresponding U-shaped channel in the lid. The
plurality of medial sealing beads most preferably extends over
substantially the entire distance between rounded corners and
defines an arched line therebetween. The medial sealing beads most
preferably blend with the rounded corners such as in preferred
embodiments where the medial sealing beads are tangent with the
rounded corners at their end portions. In particularly preferred
embodiments, the medial sealing beads have an arched profile away
from the lateral walls upon which they are disposed and the lateral
walls are generally planar. Likewise in a particularly preferred
embodiment the lateral walls upon which the sealing beads are
disposed have an upper portion and a lower portion and the medial
sealing beads are located proximate to the upper portions of the
lateral walls on which they are disposed such as where the sealing
beads are disposed at substantially two-thirds the height of the
lateral wall. In such cases the medial sealing beads may have a
maximum projection away from its lateral wall at substantially the
center line of the lateral wall.
[0019] A particularly preferred container is a thermoformed
disposable lidded container comprising a substantially generally
rectangular receptacle portion having (i) a bottom and (ii) a side
wall defining (iii) an upper aperture, the receptacle portion being
further provided with a rectangular brim extending around the upper
aperture the brim including (i) a U-shaped profile portion defining
(ii) a plurality of rounded corner brim portions and (iii) a
plurality of outer lateral brim walls extending between the rounded
brim corner portions. The outer brim walls are configured such that
their surfaces are substantially linear along a direction between
adjacent brim corner portions interconnected thereby. The container
also has a lid having (i) a rectangular sealing channel with
rounded corners adapted to fit over the brim thereby forming a
sealed container with the receptacle portion. The outer lateral
brim walls are provided with a plurality of medial sealing beads
characterized in that (i) the medial sealing beads project away
from the respective outer lateral brim walls the maximum distance
at a center portion thereof between and distal to the corners, with
lesser projections away from the outer lateral brim wall at its end
portions proximate to the corners and (ii) the medial sealing beads
extend over the major portion of the length of the outer brim wall
upon which it is disposed between adjacent corners. Most preferably
each lateral brim wall is provided with a medial sealing bead and
the lids are hinged to the receptacle.
[0020] In preferred aspects of the invention, there are provided
integrally formed ensembles of interconnected and separable
containers each of which includes an associated lid as described
and illustrated hereinafter. In these embodiments the lids are
generally co-planar with the upper aperture of their associated
cups and the containers are separably joined to one another by
tearable portions which are scored and/or perforated. Preferably
the lids are hinged to their associated cups by way of a perforate
and/or scored hinged portion of the integrally formed ensemble and
the containers are likewise separately joined by tearable portions
that are scored. Most preferably the lids are generally planar
while the cups are of substantial depth. For example, the cup may
have a depth of an inch and a quarter or so while the lid would
have an overall thickness of less than %14 inch.
BRIEF DESCRIPTION OF DRAWINGS
[0021] The invention is described in detail below with reference to
the drawings, wherein like numerals designate similar parts and
wherein:
[0022] FIG. 1 is a view in perspective of an integrally
thermoformed container/lid ensemble constructed in accordance with
the present invention;
[0023] FIG. 2 is a view in elevation of a receptacle of the present
invention provided with a medial sealing bead about the four (4)
straight portions of its brim;
[0024] FIG. 3 is a top view of a receptacle of the present
invention provided with medial sealing beads;
[0025] FIG. 4 is an enlarged schematic view illustrating the
profile of the medial sealing bead; and
[0026] FIG. 5 is a schematic view of a single container in profile
illustrating alternate locations of medial sealing beads.
DETAILED DESCRIPTION
[0027] The invention is described in detail below with reference to
several embodiments. Modifications of 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.
[0028] Referring to FIG. 1, there is shown an ensemble 10 of
integrally formed separable containers including a first array 12
of containers and a second array 14 of containers arranged on
either side of a medial axis 16. The containers are separably
joined to one another by a plurality of tear portions indicated by
dashed lines such as portions 18, 20. The tear portions may be
scored portions and are most preferably scored perforated
portions.
[0029] First array 12 of containers includes a receptacle or cup 22
having an upper aperture 24 as well as a rectangular brim 26. A lid
28 is hingedly coupled to cup 22 by way of scored hinge portion 30
which is preferably a perforate scored portion as well. Lid 28 also
has a channel 32 with a rectangular profile which cooperates with
brim 26 (which also has a rectangular profile) to form a closed
container. That is to say, upon pivotal motion of lid 28 about
hinge portion 30, the lidded container including cup 22 and lid 28
forms a sealed container when the lid is secured to the brim.
[0030] The profiles of lid 28 and brim 26 of cup 22 are likewise
seen in FIG. 5. FIG. 5 has the same container shape as are seen in
FIGS. 1-4 except that the sealing beads are shown at alternative
locations, discussed further below.
[0031] Referring again to FIG. 1, it is seen that array 12 also
includes a cup 34 with an upper aperture 36 and a brim 38 as well
as a lid 40 with a channel 41 secured to cup 34 by way of hinge 42.
Still further included in array 12 is a third container including
cup 44 with upper aperture 46, brim 48, lid 50 with a channel 51
secured by way of hinge 52.
[0032] Second array 14 of sealable containers includes: (i) a cup
54 with an upper aperture 56 and brim 58, lid 60 with channel 62
and a hinge 63; (ii) a cup 64 with an upper aperture 66, brim 68,
lid 70 with a channel 72 and a hinge 74; and (iii) cup 76 with an
upper aperture 78 and a brim 80, lid 82 with a channel 84 attached
to cup 76 by way of hinge 85.
[0033] Each of the cups and lids 34-82 has the features of cup 22
and lid 28, discussed in more detail below. For example, the
channels 32, 41 and so on have the shape shown schematically in
FIG. 5, except that in FIGS. 1-4 the sealing beads are shown on the
outer lateral walls of the sealing brim. Preferably the channels,
such as channel 32, 41, 51 and so forth, have a U-shaped profile as
do the brims such as brims 26, 38, 48 and so forth, as shown in
FIGS. 1 and 5. Note in FIGS. 1 and 5 the brims and channels have
U-shaped profiles provided with flat inner and outer walls, except
where the sealing bead is formed. Hinges, such as hinges 30 and 42
are also scored as shown by the dotted lines in FIG. 1 and may also
be perforate scored if so desired. Each receptacle portion or cup
also has a surround such as surround 86 and surround 88 located
outside the brim on its lower edge as is seen in FIG. 1 and perhaps
better appreciated from FIGS. 2 and 3 where the shaped construction
of the sidewalls of the receptacle portion of the containers is
likewise appreciated. That is to say the rounded corners of the
containers as well as the recessed sidewalls 90 of the various cups
may also be seen.
[0034] As will be appreciated from FIGS. 1 through 5, each
container includes a cup or receptacle portion as well as an
associated lid. The receptacle portions have a brim with a
plurality of straight portions between rounded corners as will be
particularly appreciated by reference to FIGS. 2 and 3.
[0035] FIG. 2 is a partial view in elevation of a portion of a
container of FIG. 1 including receptacle or cup 22 while FIG. 3 is
a top plan view thereof.
[0036] Receptacle portion 22 has a brim 26 provided with four
linear segments 100, 102, 104, and 106. The linear segments are
interconnected by rounded corners 108, 110, 112, and 114.
Preferably the brim is U-shaped in profile as shown with generally
flat (except for sealing beads) inner and outer sidewalls which
define a U-shape together with its top. Likewise, the channels are
most preferably U-shaped with flat walls cooperating to form a seal
with the rectangular, U-shaped brim when the parts are engaged.
Each of the linear segments 100, 102, 104 and 106 of the brim has a
medial sealing bead, 116, 118, 120, and 122 as shown extending
substantially over the entire length, L, of the linear segment and
blending with the corners between the linear segments. Most
preferably, the medial sealing beads are arched in shape as shown
and tangent to the corner portions of the brim and are configured
such that they generally progressively increase in projection from
the walls of the brim as the distance from the adjacent corner
portions increases. That is to say, the sealing beads project away
from the brim a maximum distance at the center portion of the
linear segment where they are disposed. This feature is perhaps
best appreciated by reference to FIGS. 2 and 4. FIG. 4 is an
enlarged schematic view in section along line 4-4 of FIG. 2, that
is, at the center point of linear segment 104. Here the sealing
bead 120 has its maximum projection which is shown as its maximum
projection, P, away from surface 105 of brim segment 104 which may
be about 8 mils (thousandths of an inch) or so for a two ounce
container. In the embodiment shown in FIGS. 1 through 4, the bead
is disposed at a height which is approximately two-thirds the
height, H, of brim portion 104 above surround 86. Other positions
of sealing beads are possible. That is to say, the sealing bead is
located on wall 105 of brim portion 104 as shown in the diagram.
The beads are in the same location on all straight segments of the
brims on the containers shown in FIG. 1, as will be appreciated
from FIGS. 2 and 3, especially.
[0037] There is shown schematically in FIG. 5 alternate locations
of sealing beads of the present invention.
[0038] FIG. 5 illustrates a container including a cup portion 152
as well as a lid 154. The cup portion has a brim 156 which might
include a sealing bead on its inner wall as indicated at 158
instead of on the outer wall as in shown in FIGS. 1 through 4.
Likewise, lid 154 may include a channel 160 provided with sealing
beads on its inner wall as indicated at 162 and/or on its outer
wall as indicated at 164. It is believed that the embodiment shown
in FIGS. 1 through 4 is preferable for many containers of the
present invention; however, the beads as described herein may be
suitably located at one or more locations as is shown in FIG.
5.
[0039] The length of the maximum projection, P, away from the
sidewall of the brim upon which the medial sealing bead is disposed
has an impact on the seal improvement for the container. It is
found in accordance with the present invention, that a seal with a
maximum projection of 8 mils performed substantially better than a
seal having a maximum of 0.005 inches or 5 mils. It is seen in the
vinegar/oil leak test the percent pass for the 8 mil bead was 96
percent while only 46 percent of the 5 mil bead containers passed,
suggesting that the projection distance impacts performance. Thus,
if one looks at FIG. 3 the linear length, L, of a straight portion
of the brim may be for example one inch or so for a two ounce
container where the optimal projection length away from the
sidewall of the brim may be about 8 mils. Thus suitably a preferred
ratio of P/L is preferably from about 0.01 to about 0.0075. That is
to say, for a one inch straight sidewall length the projection
should be from about 7.5 to 10 mils or so. In other embodiments,
preferred P/L ratios may vary. For example, P/L ratios of from
about 0.0025 to about 0.025 are within the scope of the invention
as are P/L ratios of from about 0.005 to about 0.015.
[0040] 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. When thermoformed, the containers are made from sheet
having a caliper of from bout 5 to 30 mils; typically from about 10
to 20 mils.
[0041] Alternatively, the lid/container ensemble may be injection
molded; however, thermoforming is generally preferred.
[0042] The present invention provides a unique combination of leak
resistance and ease of capping. This latter feature is very
important especially for thermoformed articles which tend to crush
if the capping force required is too high. This will be appreciated
from the discussion which follows.
[0043] Product Testing
[0044] Products were tested for water or vinegar/oil leakage as
follows: (a) with the containers still inter-connected and with
their lids still connected, they were filled with water or a 50/50
mixture of vinegar and vegetable oil; (b) the containers were then
closed; (c) the containers were then separated from one another and
placed on blotter paper; (d) each container was then placed on a
side thereof, the side selected not having a hinge or tab; (e) the
container was allowed to remain on its side for up to ten minutes;
(f) if the container did not leak in 10 minutes, it was recorded as
a pass; all others were recorded as failures; and (g) the test was
repeated for another container ensemble, but the containers were
placed on their sides opposite to those of the first trial.
[0045] The capping force test was conducted as follows: (a) with
the container uncapped, they were separated from six-pack units,
care was taken not to tear or damage the brim of the receptacle;
(b) the test specimen, including receptacle and hinged cap, was
placed in an automated capping tester with a preset gauge height
sufficient to receive the container without interference; (c) the
lid was folded into a capping position while a force gauge was
zeroed and the speed set to 21/2"/minute; (d) the tester drive was
activated and the cross arm advanced until the cap was fully seated
on the receptacle; (d) the container was inspected for damage; and
(e) the capping force required was recorded.
[0046] Initially the containers shown in FIG. 1 were made without
medial sealing beads and did not perform well in the leak test.
Initial trials involved making the lids tighter; however more than
half of these containers were crushed during capping. It was found
however, that with a required capping force of four (4) pounds or
so, no containers were crushed. The inventive design was conceived
and tested after these initial failures. Composite results are
shown in Table 1. Table 1 reflects the early approach toward
improving leak testing by making a tighter cap, but as can be seen
from Table 1 this resulted in an unacceptably high rate of crushing
of the container during capping. More importantly, it is seen from
the data that with the present invention the containers are
remarkably more leak resistant.
1TABLE 1 Leak/Cap Testing Capping % Crushed Capping % Crushed Force
When Force When Avg 6 Water Vinegar/ with Capped without Capped
Pack Leak Oil Leak Hinge with Hinge without Weight (% Pass) (%
Pass) (lb.) Hinge (lb.) Hinge (grams) Invention 100% 71% 4.8 -- 4.4
-- 31.694 Tooling Tooling A 0% 0% 8.5 58% 8.2 58% 29.759 Without
Sealing Bead Tooling B 75% 0% 4.1 -- 4.3 -- 29.870 Without Sealing
Bead Vinegar/Oil Leak Breakdown % Pass (0.008" Bead) 96% % Pass
(0.005" Bead) 46%
[0047] In Table 1 there is seen a dramatic increase in leak
resistance with the invention design, without the need for an
increase capping force and associated crushing of the
containers.
* * * * *