U.S. patent application number 10/911044 was filed with the patent office on 2005-01-20 for sealable portion cups and lids therefor.
Invention is credited to Baker, Loren G., Rush, Jonathan E., Van Handel, Gerald J., Whitmore, Rebecca E..
Application Number | 20050011898 10/911044 |
Document ID | / |
Family ID | 34798995 |
Filed Date | 2005-01-20 |
United States Patent
Application |
20050011898 |
Kind Code |
A1 |
Van Handel, Gerald J. ; et
al. |
January 20, 2005 |
Sealable portion cups and lids therefor
Abstract
A container ensemble for food packaging comprising a
substantially planar lid member formed of a polymeric material
which has a plurality of substantially planar lids which are
integrally formed and separably joined to each other, each of the
lids including a sealing channel around its perimeter and a skirt
extending outwardly therefrom. The lid member is provided with
tearable portions to facilitate separation. The other component of
the ensemble is a cup member formed of a polymeric material
defining a plurality of cups which are integrally formed and also
separably joined to each other, the cups including a bottom, a
sidewall, and a brim about an upper opening of each cup. Each cup
has a skirt extending outwardly from its brim provided with
tearable portions to facilitate separation. The sealing channels of
the lids of the lid member are adapted to mate with the brims of
the cups to provide a plurality of separably joined sealed
containers when the lid member and cup member are joined in sealing
engagement; the ensemble being thereby adapted for sequentially:
(i) receiving serving portions of food in a plurality of cups; (ii)
lidding the cups to provide sealed containers containing individual
portions; (iii) separating the sealed containers; and (iv)
distributing the portions.
Inventors: |
Van Handel, Gerald J.;
(Neenah, WI) ; Whitmore, Rebecca E.; (Chilton,
WI) ; Baker, Loren G.; (Saylorsburg, PA) ;
Rush, Jonathan E.; (Easton, PA) |
Correspondence
Address: |
Michael W. Ferrell, Esq.
Ferrells, PLLC
P.O. Box 312
Clifton
VA
20124-1706
US
|
Family ID: |
34798995 |
Appl. No.: |
10/911044 |
Filed: |
August 4, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10911044 |
Aug 4, 2004 |
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10751786 |
Jan 5, 2004 |
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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: |
220/507 |
Current CPC
Class: |
B65D 2543/00296
20130101; B65D 1/265 20130101; B65D 2543/0074 20130101; B65D
2543/00555 20130101; B65D 2543/00805 20130101; B65D 2543/00194
20130101; B65D 43/162 20130101; B65D 2543/00694 20130101; B65D 1/30
20130101; B65D 2543/00101 20130101; B65D 2543/00537 20130101; B65D
43/0212 20130101; B65D 21/0233 20130101; B65D 2543/00509 20130101;
B65D 2543/00953 20130101; B65D 2543/00842 20130101; B65D 2543/00629
20130101; B65D 43/021 20130101 |
Class at
Publication: |
220/507 |
International
Class: |
B65D 041/06 |
Claims
What is claimed is:
1. A container ensemble for food packaging comprising: a) a
substantially planar lid array member formed of a polymeric
material defining a plurality of substantially planar lids which
are integrally formed and separably joined to each other, each of
the lids including a sealing channel around its perimeter and a
skirt extending outwardly therefrom provided with tearable portions
to facilitate separation; b) a cup array member formed of a
polymeric material defining a plurality of cups which are
integrally formed and separably joined to each other, each of the
cups including a bottom, a sidewall, a brim about an upper opening
of each cup and a skirt extending outwardly from its brim, wherein
the skirts of each cup include tearable portions to facilitate
separation; c) the sealing channels of the lids of the lid member
being adapted to mate with the brims of the cups to provide a
plurality of separably joined sealed containers when the lid member
and cup member are joined in sealing engagement; the ensemble being
thereby adapted for sequentially: (i) receiving serving portions of
food in a plurality of cups; (ii) lidding the cups to provide
sealed containers containing individual portions; (iii) separating
the sealed containers; and (iv) distributing the portions.
2. The container ensemble according to claim 1, thermoformed from
thermoplastic sheet.
3. The container ensemble according to claim 1, wherein said lid
member is integrally fabricated with said cup member.
4. The container ensemble according to claim 1, wherein said lid
member and said cup member are fabricated as separate
components.
5. The container ensemble according to claim 1, wherein the
plurality of separably joined cups are arranged in an N.times.M
array, N and M being independently selected integers from 1 to
6.
6. The container ensemble according to claim 1, wherein the
plurality of separably joined lids are arranged in an N.times.M
array, N and M being independently selected integers from 1 to
6.
7. A container ensemble for food packaging comprising: a) a
substantially planar lid array member formed of a polymeric
material defining a plurality of substantially planar lids which
are integrally formed and separably joined to each other in an
N.times.M array, each of the lids including a sealing channel
around its perimeter and a skirt extending outwardly therefrom
provided with tearable portions to facilitate separation; b) a cup
array member formed of a polymeric material fabricated as a
separate component with respect to the lid member defining a
plurality of cups which are integrally formed and separably joined
to each other in an N.times.M array, the cups including a bottom, a
sidewall, a brim about an upper opening of each cup and a skirt
extending outwardly therefrom, wherein the skirts of each cup are
provided with tearable portions to facilitate separation; c) N and
M are independently selected integers of from 1 to 6; d) the
sealing channels of the lids of the lid member being adapted to
mate with the brims of the cups to provide N.times.M separably
joined sealed containers when the lid member and cup member are
joined in sealing engagement; the ensemble being thereby adapted
for sequentially: (i) receiving serving portions of food in a
plurality of cups; (ii) lidding the cups to provide sealed
containers containing individual portions; (iii) separating the
sealed containers; and (iv) distributing the portions.
8. The container ensemble according to claim 7, wherein N and M are
2 or 3.
9. The container ensemble according to claim 7, wherein N is 2 and
M is 3.
10. The container ensemble according to claim 7, wherein the cups
and lids are separably joined by tearable portions that are
perforated.
11. The container ensemble according to claim 7, wherein the cups
and lids are separately joined by tearable portions that are
scored.
12. The container ensemble according to claim 7, wherein each
container has a fill volume of from about 1 to about 8 fluid
ounces.
13. The container ensemble according to claim 7, wherein each
container has a fill volume of from about 1 to about 6 fluid
ounces.
14. The container ensemble according to claim 7, wherein each
container has a fill volume of from about 1 to about 4 fluid
ounces.
15. The container ensemble according to claim 7, wherein each
container has a fill volume of about 2 fluid ounces.
16. The container ensemble according to claim 7, wherein each
container has a fill volume of about 6 fluid ounces.
17. The container ensemble according to claim 7, made from a
thermoplastic composition comprising a polystyrene polymer
composition.
18. The container ensemble according to claim 17, wherein the
polystyrene polymer composition comprises high impact
polystyrene.
19. The container ensemble according to claim 17, wherein the
polystyrene polymer composition comprises rubberized
polystyrene.
20. The container ensemble according to claim 17, wherein the
polystyrene polymer composition is oriented polystyrene.
21. The container ensemble according to claim 7, made from a
thermoplastic composition comprising a polyolefin polymer.
22. The container ensemble according to claim 21, wherein the
polyolefin polymer is polypropylene.
23. The container ensemble according to claim 21, wherein the
polyolefin polymer is polyethylene.
24. The container ensemble according to claim 7, made from a
thermoplastic composition comprising polyethylene
terephthalate.
25. The container ensemble according to claim 7, wherein the brims
of the cups have profiles which are U-shaped and the lids are
provided with corresponding U-shaped channels.
26. The container ensemble according to claim 7, wherein the lids
and cups cooperate to form substantially continuous seals around
the opening of the cups when the lid member and cup member are
joined together in sealing engagement.
27. The container ensemble according to claim 7, wherein: a) the
brims of the cups being further provided with: (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; and b) the lids are 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 c) 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.
28. The container ensemble according to claim 27, wherein the
plurality of medial sealing beads extends over substantially the
entire distance between rounded corners.
29. The container ensemble according to claim 27, wherein the
plurality of medial sealing beads defines an arched line between
adjacent rounded corners.
30. The container ensemble according to claim 27, wherein the
medial sealing beads blend with the rounded corners at ends of the
medial sealing beads.
31. The container ensemble according to claim 27, wherein the
medial sealing beads are flush with rounded corners at their end
portions.
32. The container ensemble according to claim 28, wherein the
medial sealing beads have an arched profile away from the lateral
walls upon which they are disposed.
33. The container ensemble according to claim 28, 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.
34. The lidded container according to claim 28, 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.
35. The lidded container according to claim 28, wherein the medial
sealing beads have a maximum projection away from the lateral wall
at substantially the center line of the lateral wall.
36. A method of distributing individual serving portions of a food
item selected from condiments, dressings, sauces and side dishes
comprising the sequential steps of: a) disposing the serving
portions of the food item in a plurality of cups provided in a cup
array formed of a polymeric material defining a plurality of cups
which are integrally formed and separably joined to each other, the
cups including a bottom, a sidewall, a brim about an upper opening
of each cup, and a skirt extending outwardly from its brim, wherein
the skirts of each cup are provided with tearable portions to
facilitate separation; b) joining a lid array to the cup array, the
lid member being substantially planar and formed of a polymeric
material defining a plurality of substantially planar lids which
are integrally formed and separably joined to each other, each of
the lids including a sealing channel around its perimeter and a
skirt extending outwardly therefrom provided with tearable portions
to facilitate separation; c) whereupon joining the lid member and
the cup member the sealing channels of the lids of the lid member
mate with the brims of the cups of the cup member to provide a
plurality of separably joined, food containing sealed containers;
d) separating the sealed containers from one another; and e)
distributing the individual portions.
37. A system for food packaging comprising an ensemble of: a) a
nested stack of substantially planar lid array members formed of a
polymeric material each defining a plurality of substantially
planar lids which are integrally formed and separably joined to
each other, each of the lids including a sealing channel around its
perimeter and a skirt extending outwardly therefrom provided with
tearable portions to facilitate separation, wherein the sealing
channel defines a top recess on each lid; b) a nested stack of cup
array members formed of a polymeric material each member defining a
plurality of cups which are integrally formed and separably joined
to each other, the cups including a bottom, a sidewall, a brim
about an upper opening of each cup and a skirt extending outwardly
from its brim, wherein the skirts of each cup include tearable
portions to facilitate separation, wherein further the bottom of
each cup is configured to fit with the top recess of a lid such
that an assembled lid/cup ensemble of sealed containers is securely
stackable; c) the sealing channels of each lid of the lid members
being adapted to mate with the brims of the cups of a cup member to
provide a plurality of separably joined sealed containers when a
lid member and cup member are joined in sealing engagement; an
assembled lid/cup ensemble of sealed containers being thereby
adapted for sequentially: (i) receiving serving portions of food in
a plurality of cups; (ii) lidding the cups to provide sealed
containers containing individual portions; (iii) separating the
sealed containers; and (iv) distributing the portions.
Description
CLAIM FOR PRIORITY
[0001] This non-provisional application is a continuation-in-part
of co-pending U.S. patent application Ser. No. 10/751,786, entitled
"Lidded Container with Linear Brim Segments and Medial Sealing
Beads" (Attorney Docket 2391-1/GP-01-31-1), filed Jan. 5, 2004,
which 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" (Attorney Docket 2391/GP-01-31), filed Jun.
6, 2003, which claims the benefit of the filing date of U.S.
Provisional Patent Application Ser. No. 60/389,533, filed Jun. 18,
2002. The priorities of the foregoing applications are hereby
claimed.
TECHNICAL FIELD
[0002] The present invention relates to disposable containers with
lids for packaging fresh foods for distribution. Particularly
preferred embodiments inclusive of 2, 4 and 6 ounce containers for
sauces and condiments are thermoformed on complimentary sheets
which may be joined in sealing engagement to each other and
thereafter separated to supply individual portions.
BACKGROUND
[0003] 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.
[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. In this
respect, German Patent DE 100 12 364 of von der Worth discloses
separable egg cartons arranged in a planar array. See also DE 100
12 364; FR 2 763 314; and FR 1 278 149.
[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] 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.
[0013] 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.
[0014] Likewise, existing containers, especially relatively small
containers, are difficult to individually fill and seal, making the
process prohibitively time consuming or requiring equipment and
skills not generally available at homes, catering establishments
and restaurants.
SUMMARY OF INVENTION
[0015] The present invention provides food containers which are
easily filled and sealed while the containers are connected to one
another and then separated into individual containers containing a
serving. Preferably the lids and cups form substantially continuous
seals between them so that the containers are substantially liquid
proof; it being understood that the seal, while highly effective,
especially when viewed in light of the low cost nature of the
articles, is of course less than perfect where the seal formed
might allow a few drops of moisture to penetrate when a sealed
container is partially filled with water and shaken; but
compression, effort and/or agitation is required to remove more
than a few drops of liquid. The containers are thus especially
suitable for liquid or semi-liquid sauces, condiments, dressings,
side dishes and so forth that are prepared and fresh-packaged
shortly before consumption.
[0016] There is provided in one aspect of the invention a container
ensemble for food packaging comprising: a substantially planar lid
array member formed of a polymeric material defining a plurality of
substantially planar lids which are integrally formed and separably
joined to each other, each of the lids including a sealing channel
around its perimeter and a skirt extending outwardly therefrom
provided with tearable portions to facilitate separation; a cup
member formed of a polymeric material defining a plurality of cups
which are likewise integrally formed and separably joined to each
other, the cups including a bottom, a sidewall, and a brim about an
upper opening of each cup. Each cup further includes a skirt
extending outwardly from its brim provided with tearable portions
to facilitate separation. The sealing channels of the lids of the
lid member are adapted to mate with the brims of the cups to
provide a plurality of separably joined sealed containers when the
lid member and cup member are joined in sealing engagement. The
ensemble is accordingly adapted for sequentially: (i) receiving
serving portions of food in a plurality of cups; (ii) lidding the
cups to provide sealed containers containing individual portions;
(iii) separating the sealed containers; and (iv) distributing the
portions. The container ensemble is preferably thermoformed from
thermoplastic sheet.
[0017] The ensemble may be formed from a single sheet of
thermoplastic resin so that the lid member is integrally fabricated
with the cup member and is optionally hinged thereto. The tearable
portions are scored and/or perforated. The container ensemble is
advantageously fabricated from different sheets, optionally sheets
of different color, that is, the lid member and said cup member are
fabricated as separate components wherein the cups and lids have
different color or are made from different caliper material or from
different polymeric materials. The container ensemble is typically
configured such that the plurality of separably joined cups are
arranged in an N.times.M array, N and M being independently
selected integers from 1 to 6. Likewise, the lids are arranged in
an N.times.M array, N and M being perhaps most preferably 2 and 3,
but either integer may be 1 in some cases.
[0018] An especially preferred embodiment is where the brims of the
cups are further provided: a plurality of rounded corner brim
portions; and 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; and the lids
are suitably provided with: a plurality of lid rounded corner
portions; and 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 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:
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
the medial sealing beads extend over the major portion of the
length of the lateral wall between adjacent corners upon which they
are disposed. Preferably, the plurality of medial sealing beads
extends over substantially the entire distance between rounded
corners; and preferably the plurality of medial sealing beads
defines an arched line between adjacent rounded corners such that
the medial sealing beads blend with the rounded corners at their
ends. Most preferably, the medial sealing beads are flush with
rounded corners at their end portions and have an arched profile
away from the lateral walls upon which they are disposed. In a
typical embodiment, 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, for example, 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.
[0019] In an especially preferred embodiment, the medial sealing
beads have a maximum projection away from the lateral wall at
substantially the center line of the lateral wall.
[0020] In another aspect of the invention, there is provided a
method of distributing individual serving portions of a food item
selected from condiments, dressings and side dishes comprising the
sequential steps of: (1) disposing the serving portions of the food
item in a plurality of cups provided in a cup array member formed
of a polymeric material defining a plurality of cups which are
integrally formed and separably joined to each other, the cups
including a bottom, a sidewall, and a brim about an upper opening
of each cup, each cup further including a skirt extending outwardly
from its brim, the skirts of each cup including tearable portions
to facilitate separation; (2) joining a lid array member to the cup
member, the lid array member being substantially planar and formed
of a polymeric material including a plurality of substantially
planar lids which are integrally formed and separably joined to
each other, each of the lids including a sealing channel around its
perimeter and a skirt extending outwardly therefrom provided with
tearable portions to facilitate separation; (3) whereupon joining
the lid member and the cup member the sealing channels of the lids
of the lid member mate with the brims of the cups to provide a
plurality of separably joined sealed containers; (4) separating the
sealed containers; and (5) distributing the individual portions.
The serving portions of food items may be selected from ketchup,
mayonnaise, mustard, relish, tartar sauce and salad dressing and
the like.
[0021] A still further aspect of the invention is a packaging
system including: (a) a nested stack of substantially planar lid
array members formed of a polymeric material each defining a
plurality of substantially planar lids which are integrally formed
and separably joined to each other, each of the lids including a
sealing channel around its perimeter and a skirt extending
outwardly therefrom provided with tearable portions to facilitate
separation, wherein the sealing channel defines a top recess on
each lid; (b) a nested stack of cup members formed of a polymeric
material defining a plurality of cups which are integrally formed
and separably joined to each other, the cups including a bottom, a
sidewall, and a brim about an upper opening of each cup, each cup
further including a skirt extending outwardly from its brim, the
skirts of each cup including tearable portions to facilitate
separation, wherein further the bottom of each cup is configured to
fit with the top recess of a lid such that an assembled lid/cup
ensemble of sealed containers is securely stackable; (c) the
sealing channels of each lid of the lid members being adapted to
mate with the brims of the cups of a cup member to provide a
plurality of separably joined sealed containers when the lid member
and cup member are joined in sealing engagement; an assembled
lid/cup ensemble of sealed containers being thereby adapted for
sequentially: (i) receiving serving portions of food in a plurality
of cups; (ii) lidding the cups to provide sealed containers
containing individual portions; (iii) separating the sealed
containers; and (iv) distributing the portions.
[0022] There is 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 and 6 ounce containers. In still other
cases, 1 or 1.5 ounce containers are preferred. 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 arcuate cross section or profile as is
shown in FIG. 4 approximately one third the distance down from the
top of the brim. The bead is at its fullest protrusion or
projection at the center line of the straight side of the cup and
is flush with to the corner radii on either side. The maximum
height of the bead is most preferably 0.008 inches in the
embodiments tested, progressively diminishing or feathering out to
0.000" so as to be flush at 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 be flush with the
corner on both ends of the arc as is best appreciated from FIG. 3,
where it is seen that the "end-to-end" curvature of the sealing
beads is quite subtle, as is the case when the radius of curvature
is quite large. Without intending to be bound by any theory, it is
believed that the cup bead feature enhances the sealing function
because it increases pressure between the lid and cup brim where 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 line of contact and exerts pressure 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.
[0023] 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 may be 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.
[0024] Instead of being made by way of thermoforming, the inventive
containers may be made by injection molding if so desired. For ease
of illustration, the beads are shown as being made by injection
molding. Typically, each container has a fill volume of from about
1 to about 8 fluid ounces, such as from about 1 to about 4 or 6
fluid ounces, 6-ounce and 4-ounce containers sometimes being
preferred. In the embodiments specifically illustrated hereinafter,
the containers have a fill volume of about 2 fluid ounces and are
particularly useful for condiments.
BRIEF DESCRIPTION OF DRAWINGS
[0025] The invention is described in detail below with reference to
the drawings, wherein like numerals designate similar parts and
wherein:
[0026] FIG. 1 is an exploded view in perspective of a thermoformed
container/lid ensemble constructed in accordance with the present
invention wherein the lids are thermoformed from one sheet of
thermoplastic resin and the cups are thermoformed from another
sheet of thermoplastic resin;
[0027] FIG. 2 is a view in elevation of an individual cup of the
present invention provided with a medial sealing bead about the
four (4) straight portions of its brim;
[0028] FIG. 3 is a top view of an individual cup of the present
invention provided with medial sealing beads;
[0029] FIG. 4 is an enlarged schematic view illustrating the
profile of the medial sealing bead;
[0030] FIG. 5 is an exploded schematic view of a portion of a
single container in profile illustrating alternate locations of
medial sealing beads;
[0031] FIG. 6 is a top plan view of a stack of nested lid array
members;
[0032] FIG. 7 is a view in elevation of a stack of nested lid array
members;
[0033] FIG. 8 is a plan view of a stack of nested cup array
members; and
[0034] FIG. 9 is a view in elevation of a stack of nested cup array
members.
DETAILED DESCRIPTION
[0035] 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.
[0036] Referring to FIG. 1, there is illustrated a container
ensemble 10 including a substantially planar lid array member 11
including lids 12, 14, 16, 18, 20 and 22 in a 2.times.3 arrangement
as well as a cup array member 24 including cups 26, 28, 30, 31, 32
and 34. Both the lid and cup members are conveniently formed from a
sheet of thermoplastic material as is well known in the art.
[0037] Each lid has a sealing channel such as channel 36 which is
configured to cooperate with the corresponding brim cup to form a
seal; that is channel 36 is configured to cooperate with brim 48 to
form a sealed container which may be separated from the others
after sealing. The lids are separably joined to each other by a
skirt such as skirt 40 which has a scored or perforate tearable
portion 42 so that the lids can be separated from one another.
[0038] Each cup of cup member 24 includes a bottom 44, a sidewall
46 and a brim 48 extending around an opening 50 of each cup. There
is additionally provided a skirt 52 around each cup extending
outwardly from its brim. The skirts include scored or perforate
portions such as portions 54, 56 so that the cups can be separated
from each other.
[0039] The profiles of lid 22 and brim 48 of cup 26 are likewise
seen in FIG. 5. FIG. 5 has the same container shape as seen in
FIGS. 1-4 except that the sealing beads are shown at alternative
locations, discussed further below.
[0040] As will be appreciated from FIGS. 1 through 5, each
container includes a cup or receptacle portion as well as an
associated lid portion which may be joined together and sealed
before separation. Each receptacle portion has a brim with a
plurality of straight portions between rounded corners as will be
particularly appreciated by reference to FIGS. 2 and 3.
[0041] FIG. 2 is a view in elevation of cup 26 of FIG. 1, while
FIG. 3 is a top plan view thereof. Cup 26 has a brim 48 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 substantially 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 flush with 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 indicated as P,
away from surface 105 of brim segment 104 which may be about 8 mils
(thousandths of an inch) or so for a 2-ounce container. It will be
appreciated from the Figures, especially FIG. 3, that the curvature
of the sealing beads is very subtle, that is, the beads have a very
large radius of curvature from end to end. 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 segment 104
above surround skirt 52. Other positions of sealing beads are
possible. That is to say, the sealing bead is located on wall
surface 105 of brim portion segment 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.
[0042] Each of the cups and lids has all of the features of cup 26
and lid 22, discussed in more detail below. For example, the lid
channels and brims 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 have a
U-shaped profile as do all of the brims 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. Each receptacle portion or cup also has a surround
or skirt extending outwardly from 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 58 of the various cups may also be seen.
[0043] There are shown schematically in FIG. 5 alternate locations
of sealing beads of the present invention.
[0044] FIG. 5 illustrates a container including a cup portion 152
as well as a lid portion 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.
[0045] 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 projection 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 2-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 0.0075 to about
0.01. 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.
[0046] 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 about 5 to 30 mils; typically from about
10 to 20 mils.
[0047] Alternatively, the lid/container ensemble may be injection
molded; however, thermoforming is generally preferred.
[0048] 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.
[0049] Product Testing
[0050] Products were tested for water or vinegar/oil leakage as
follows: (a) with the containers still inter-connected and with
their lids still inter-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.
[0051] The capping force test was conducted as follows: (a) with
the containers uncapped, individual containers were separated from
six-pack units, care being taken not to tear or damage the brim of
the cup; (b) the test specimen, including cup and cap, was placed
in an automated capping tester with a preset gauge height
sufficient to receive the container without interference; (c) if
the cup and lid were connected the lid was folded into a capping
position, containers with separate cups and lids were prepared by
placing the lid loosely in position on the cup brim; and 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 cup; (e) the container was inspected for
damage; and (f) the capping force was recorded.
[0052] Initially the containers 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 O* 4.4
O* 31.694 Tooling Tooling 0% 0% 8.5 58% 8.2 58% 29.759 A Without
Sealing Bead Tooling 75% 0% 4.1 O* 4.3 O* 29.870 B Without Sealing
Bead Vinegar/Oil Leak Breakdown % Pass (0.008" Bead) 96% % Pass
(0.005" Bead) 46% *very low percentage, believed negligible
[0053] In Table 1 there is seen a dramatic increase in leak
resistance with the invention design, without the need for
increased capping force and associated crushing of the
containers.
[0054] Referring to FIGS. 6 and 7, there is shown a nested stack
200 of lid members 202, 204 and 206 each of which includes a
plurality of nested lids such as lids 210, 212, 214, 216, 218 and
220 which are integrally formed and separably joined to each other
by skirts such as skirt 222 which includes scored or perforated
regions 224 to facilitate separation. Each individual lid has a
channel such as channel 228 around its perimeter defining a
plurality of top recesses 230, 232, 234, 236, 238 and 240 which are
configured to receive the bottoms of cups of a corresponding cup
member (FIGS. 8 and 9) so that assembled containers are securely
stackable. The channels themselves seal with the brims of
corresponding cups as discussed above.
[0055] Referring to FIGS. 8 and 9, there is shown a nested stack
250 of cup members including cup members 252, 254 and 256. Each cup
member includes a plurality of cups such as cups 260, 262, 264,
266, 268 and 269. The members are integrally thermoformed from a
sheet, for example. The cups have bottoms such as bottom 270,
sidewalls such as sidewall 272 and brims such as brim 274. The cups
further include skirts such as skirt 276 and include scores as
illustrated at 278, 280. The bottom of each cup fits with the
corresponding top recess of a lid member such as recesses 230-240
to make an assembled stack of sealed containers securely stackable
as noted above. The components of the packaging system are
compactly stored and a lid component may be used with a variety of
cup components of different volume to provide flexibility and a
minimum number of required components, while still providing color
options so that servings can be color coded, if so desired.
[0056] While the invention has been described in connection with
specific examples, modifications to those examples within the
spirit and scope of the invention will be readily apparent to those
of skill in the art. In view of the foregoing discussion, relevant
knowledge in the art and references discussed above in connection
with the Background and Detailed Description, the disclosures of
which are all incorporated herein by reference, further description
is deemed unnecessary.
* * * * *