U.S. patent application number 10/634240 was filed with the patent office on 2005-02-10 for container having a cut panel lid with a pull feature.
This patent application is currently assigned to Sonoco Development, Inc.. Invention is credited to Martin, Michael K., Morrow, J. Mark.
Application Number | 20050029267 10/634240 |
Document ID | / |
Family ID | 34116006 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050029267 |
Kind Code |
A1 |
Martin, Michael K. ; et
al. |
February 10, 2005 |
Container having a cut panel lid with a pull feature
Abstract
There is provided a container with an opening formed by cutting
a panel from the container body. A pull feature is joined to the
panel and the panel is reattached to the container to cover the
opening. The panel is reattached with a sealed, frangible interface
so that pulling the pull feature of the panel removes the panel
from the container to provide access to the contents within the
container through the opening. The pull feature may be a pull tab
joined to an outer surface of the panel or may be a pull tab and a
ring. To facilitate the formation of the sealed, frangible
interface, the ring may be positioned between an outer edge of the
panel and an inner edge of the container or may be positioned to
overhang the outer edge of the panel and to contact the container
proximate the opening. The container may also include a second
opening at an opposite end of the container that includes a closure
sealed to the container.
Inventors: |
Martin, Michael K.;
(Hartsville, SC) ; Morrow, J. Mark; (Camden,
SC) |
Correspondence
Address: |
ALSTON & BIRD LLP
BANK OF AMERICA PLAZA
101 SOUTH TRYON STREET, SUITE 4000
CHARLOTTE
NC
28280-4000
US
|
Assignee: |
Sonoco Development, Inc.
Hartsville
SC
|
Family ID: |
34116006 |
Appl. No.: |
10/634240 |
Filed: |
August 5, 2003 |
Current U.S.
Class: |
220/270 |
Current CPC
Class: |
B65D 2517/5064 20130101;
B65D 17/508 20130101; B65D 2517/5081 20130101 |
Class at
Publication: |
220/270 |
International
Class: |
B65D 017/34 |
Claims
1. A container, comprising: a container body formed by a wall; an
opening defined in the wall of the container body, the opening
being formed by cutting the wall so as to remove a panel from the
wall, the panel being sized to substantially completely cover the
opening; the panel being reattached to the container body covering
the opening so as to create a sealed, frangible interface between
the panel and the wall defining the opening; and a pull feature
joined to the panel and which, when pulled, causes detachment of
the panel from the container body along the sealed, frangible
interface and thereby removes the panel to gain access to the
contents of the container through the opening.
2. A container according to claim 1, wherein the wall defines a
generally planar end wall and a side wall joined to an outer
periphery of the end wall and extending away therefrom, and wherein
the opening is defined in the end wall.
3. A container according to claim 2, wherein the side wall defines
a second opening at an opposite end of the side wall from the end
wall, and further comprising a closure attached to the side wall to
close the second opening.
4. A container according to claim 3, wherein the closure comprises
a metal end.
5. A container according to claim 4, wherein the side wall defines
a flange encircling the second opening and the metal end is
attached to the flange by double-seaming.
6. A container according to claim 3, wherein the closure comprises
a foil membrane attached to the side wall by heat sealing.
7. A container according to claim 3, wherein the closure comprises
a cover of the same material as the container body attached to the
side wall by heat staking.
8. A container according to claim 1, wherein the panel defines an
exterior surface and the pull feature is a pull tab joined to the
exterior surface of the panel.
9. A container according to claim 8, wherein the panel is
reattached to the container body by heat staking.
10. A container according to claim 1, wherein the pull feature
includes a pull tab and a ring.
11. A container according to claim 10, wherein the panel defines an
outer edge and defines an exterior surface and the pull feature is
joined to the exterior surface of the panel such that the ring
overhangs the outer edge of the panel, so that when the panel is
reattached to the container body, the overhanging portion of the
ring engages the container body proximate the opening thus creating
the sealed, frangible interface.
12. A container according to claim 11, wherein an adhesive is
included on a surface of the overhanging portion of the ring.
13. A container according to claim 10, wherein the opening defines
an inner edge and the panel defines an outer edge, and wherein the
ring is joined to the outer edge of the panel, so that when the
panel is reattached to the container body, the surface of the ring
opposite the outer edge of the panel engages the inner edge of the
container body thus creating the sealed, frangible interface.
14. A container according to claim 13, wherein an adhesive is
included on the two surfaces of the ring such that the adhesive
joins the ring to the outer edge of the panel and creates the
sealed, frangible interface.
15. A container, comprising: a container body formed by a wall,
wherein the wall defines an opening in the container body, the
opening having an inner edge; a panel substantially completely
covering the opening, the panel having an outer edge adjacent the
inner edge of the opening; and a pull feature formed separately
from and joined to the panel, and including a ring that overhangs
the outer edge of the panel and is sealed to the container body so
as to create a sealed, frangible interface, such that pulling the
pull feature fractures the sealed, frangible interface and thereby
removes the panel to gain access to the contents of the container
through the opening.
16. A container according to claim 15, wherein the wall defines a
generally planar end wall and a side wall joined to an outer
periphery of the end wall and extending away therefrom, and wherein
the opening is defined in the end wall.
17. A container, comprising: a container body formed by a wall,
wherein the wall defines an opening in the container body, the
opening having an inner edge; a panel substantially completely
covering the opening, the panel having an outer edge adjacent the
inner edge of the opening; and a pull feature formed separately
from and joined to the panel, the pull feature including a ring
that overhangs the outer edge of the panel and extends between the
outer edge of the panel and the inner edge of the opening, the ring
being sealed to the inner edge of the opening to create a sealed,
frangible interface between the panel and container, such that
pulling the pull feature fractures the sealed, frangible interface
and removes the panel from the container.
18. A container comprising: a thermoformed container body defining
a top end of the container and a bottom end of the container,
wherein the top end includes an opening, and wherein the container
body flares outwardly from the top end to the bottom end; and a
removable lid attached to the top end of the container body
covering the opening.
19. A container according to claim 18, wherein the removable lid is
attached to the top end of the container body so as to create a
sealed, frangible interface between the removable lid and the top
end of the container body.
20. A container according to claim 19, wherein removable lid is
attached to the top end of the container by heat staking.
21. A container according to claim 18, wherein the container
defines a second opening at the bottom end of the container and a
closure attached to the bottom end to close the second opening.
22. A container according to claim 21, wherein the closure
comprises a foil membrane attached to the bottom end by conductive
heat sealing.
23. A container according to claim 18, wherein the removable lid
includes a pull feature.
24. A container according to claim 23, wherein the pull feature
includes a pull tab and a ring.
25. A container according to claim 18, wherein the removable lid is
a panel cut from the top end of the container such that the panel
is sized to substantially completely cover the opening.
26. A method of manufacturing a container, comprising the steps of:
forming a wall defining a container body; cutting the wall so as to
define an opening in the wall and to remove a panel from the wall,
wherein the panel is sized to substantially completely cover the
opening; joining a pull feature to the panel; and reattaching the
panel to the container body so as to cover the opening and create a
sealed, frangible interface between the panel and the wall defining
the opening, wherein the pull feature, when pulled, causes
detachment of the panel from the container body along the sealed,
frangible interface and thereby removes the panel.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to containers with
removable lids. More particularly the invention relates to
containers with a panel cut from the container body to form an
opening that is subsequently sealed by reattaching the panel with a
pull feature, such that the panel functions as a removable lid.
BACKGROUND OF THE INVENTION
[0002] Many consumable goods are packaged in containers with
removable lids to provide safe and convenient storage of the
consumable goods. Such consumable goods include may items used by
consumers, particularly food products. Frequently, the type of
removable lid required for the consumable good may limit the design
of the container. In addition, the production processes required to
properly store the consumable goods may also limit the design of
the removable lid.
[0003] Metal ends are commonly used to seal openings of containers.
Metal ends of standard sizes can be economically produced, can be
seamed to containers very quickly, and can be removed by consumers
quickly and easily. However, as the closure design becomes more
unique and complex the cost of the metal ends increase.
Furthermore, product spillage can contaminate the sealing surfaces
and diminish the quality of the seal of the metal end.
[0004] Heat-sealed flexible membranes are also used to seal
container openings. However, it is often the case that a heat seal
strong enough to survive harsh conditions, such as retort
sterilization processes, makes the membrane difficult for consumers
to remove. Plastic closures with screw-on tops can be applied to
containers relatively quickly but are limited in size to smaller
diameter openings. Plastic to plastic seals (such as spin welding
or heat staking) may also be used to sufficiently seal a container,
but the sealed closure cannot be easily separated to open the
container. Additional closures such as foil membranes, paper ends,
or plastic ends are applied to containers at relatively slower
speeds compared to metal ends or plastic screw-on tops, which
reduces the efficiency of those packaging processes.
[0005] Therefore, a need exists for a container with a removable
lid that withstands harsh manufacturing processes, provides
sufficient sealing abilities, and affords convenient removal by the
consumer. In addition, the manufacturing process for such a
container and removable lid should be cost-effective, timely, and
consistent.
BRIEF SUMMARY OF THE INVENTION
[0006] The invention addresses the above needs and achieves other
advantages by providing a container comprising a container body
formed by a wall with an opening defined in the wall. The opening
in one embodiment is formed by cutting the wall to remove a panel
from the wall. The panel is sized to substantially completely cover
the opening. The panel is reattached to the container body to cover
the opening and to create a sealed, frangible interface between the
panel and the wall defining the opening. A pull feature is joined
to the panel and, when pulled, causes detachment of the panel from
the container body along the sealed, frangible interface. Removal
of the panel provides access to the contents of the container
through the opening.
[0007] The opening of the container may be in an end wall and the
container may include a second opening on an end of the container
opposite the end wall. A metal end may close the second opening.
Alternatively, a foil membrane or a closure of the same material as
the container may close the second opening. The pull feature joined
to the panel may comprise a pull tab joined to the exterior surface
of the panel or may comprise a pull tab connected to a ring or
strip. If a pull tab is included, the panel may be reattached by
heat staking. Alternatively, if a pull tab and ring are included,
the pull tab may join the exterior surface of the panel and the
ring may comprise a portion of the sealed, frangible interface. The
ring may overhang the outer edge of the panel and engage the wall
of the container proximate the opening to form the sealed,
frangible interface. The ring may alternatively join the outer edge
of the panel and engage the inner edge of the wall defining the
opening to form the sealed, frangible interface. Adhesives may be
used to facilitate the various sealed, frangible interfaces.
Furthermore, a container may include any combination of closure for
the second opening and pull feature for the panel.
[0008] Another embodiment of the present invention includes a
container comprising a container body formed by a wall with an
opening defined in the wall and a panel attached with a sealed,
frangible interface between the panel and the wall defining the
opening. The panel substantially completely covers the opening. A
pull feature is joined to the panel and, when pulled, causes
detachment of the panel from the container body along the sealed,
frangible interface. Removal of the panel provides access to the
contents of the container through the opening.
[0009] A further embodiment of the present invention includes a
container comprising a thermoformed container body defining a top
end of the container and a bottom end of the container. The top end
includes an opening and the container body flares outwardly from
the top end to the bottom end. A removable lid is attached to the
top end of the container body to cover the opening.
[0010] A method for manufacturing a container is also provided. A
wall defining the container body is formed and a panel is cut from
the wall to define an opening. The panel is sized to substantially
completely cover the opening. A pull feature is joined to the panel
and the panel is reattached to the container body to cover the
opening and create a sealed, frangible interface. The pull feature
allows the panel to be detached from the container body along the
sealed, frangible interface when the pull feature is pulled. The
container body may be formed to include a second opening that may
have various closures attached to the second opening. In addition,
the pull feature may include alternative portions that allow for
various sealed, frangible interfaces.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0012] FIG. 1 is a perspective view of a container in accordance
with a first embodiment of the invention;
[0013] FIG. 2 is a perspective view of a container body as
initially formed for making the container of FIG. 1;
[0014] FIG. 3 illustrates the container body having been cut to
remove a panel from an end wall of the container body;
[0015] FIG. 4 shows a pull tab and ring having been affixed to the
panel;
[0016] FIG. 5 shows the panel having been reattached to the
container to close the opening;
[0017] FIG. 6 is a perspective view of the container illustrating
the removal of the panel by a consumer;
[0018] FIG. 7 is a schematic, cross-sectional view of the container
of FIG. 1, illustrating the ring of the pull feature located above
the cut line, with a foil membrane enclosing the second opening,
and with a product contained within the container body;
[0019] FIG. 8 is a schematic, cross-sectional view of a container,
in accordance with a second embodiment of the invention,
illustrating a container with a ring of the pull feature located
within the cut line and with a double-seamed metal end enclosing
the second opening;
[0020] FIG. 9 is a schematic, cross-sectional view of an embodiment
of a container in accordance with a third embodiment of the
invention, illustrating a container without a ring of the pull
feature and with a heat staked polymer closure enclosing the second
opening; and
[0021] FIG. 10 is a perspective view of the container of FIG.
9.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all embodiments of the invention are shown. Indeed,
the invention may be embodied in many different forms and should
not be construed as limited to the embodiments set forth herein;
rather, these embodiments are provided so that this disclosure will
satisfy applicable legal requirements. Like numbers refer to like
elements throughout.
[0023] With reference to FIGS. 1-6, a container and process for
making the container in accordance with various embodiments of the
present invention are illustrated. The container comprises a
container body 10 having a side wall 20 of generally tubular or
conical form, at least one end 27 of which defines an opening 36
closed by a removable lid comprising a panel 12 to which a pull
feature is attached, as further described below. In the first
embodiment shown in FIG. 1, the container body 10 also has a
membrane 40 that is attached to an opposite end 28 of a side wall
20 and is not intended to be removed; as an alternative to the
membrane closure 40, this closure could instead be a metal end or a
plastic end. The finished container of FIG. 1 provides a sealed
storage container for a product that is accessible by removing the
panel 12. The pull feature of panel 12 illustrated in FIG. 1
comprises a pull tab 30 and a ring 32 to facilitate the removal of
the panel from the container body 10.
[0024] The container is made by first forming the container body 10
as shown in FIG. 2. The container of FIG. 2 initially has an end
wall 22 at the end 27 of the side wall 20. The end wall 22 is
generally perpendicular to the axis about which the side wall 20
extends. The side wall 20 extends from the end 27 and terminates at
an opposite end 28. The opposite end 28 of the container body 10 of
FIG. 2 is open and defines a second opening 38.
[0025] The container body 10 is formed as a single integral piece,
such as by injection molding, blow molding, or thermoforming a
suitable polymer material. Alternative container bodies may include
various materials, but are preferably plastic materials, and may be
formed by various processes, such as thermoforming and blow molding
to list two non-limiting examples.
[0026] The end wall 22 of the embodiment shown in FIG. 2 is a
generally planar panel of constant thickness that includes a
peripheral portion 26. End walls of alternative container bodies
may be of any shape or any size relative to the side wall 20; as an
example, the end wall can be shaped to be non-planar so as to allow
for distortion or expansion at high temperatures. The end 27 of
side wall 20 joins the peripheral portion 26 of the end wall 22,
and the side wall extends away from the end wall until terminating
at the opposite end 28. The side wall 20 of FIG. 2 includes an
outward frustoconical flare from the end wall 22 to the opposite
end 28 and includes an opposite end with a cross sectional
thickness greater than the end 27 of the side wall. The additional
thickness provides structural support for the container because the
opposite end 28 preferably functions as the bottom of the finished
container body 10. Alternative container bodies may be of any shape
or size and the side wall 22 may extend away from the end wall 20
at any angle relative to the end wall and the angle may also change
as the side wall extends further from the end wall. The thickness
of side wall 22 may be constant from the end 27 to the opposite end
28 or may change along any portion of the side wall 22.
[0027] Once the container body 10 has been made, the wall of the
container body is cut to remove a panel 12 and to define an opening
36 in the container body. The cutting may be accomplished in
various ways, including but not limited to cutting with a knife, a
laser, an ultrasonic device, or the like. The panel 12 of FIG. 3 is
cut out along a cut line spaced radially inward from the outer
periphery of the end wall 22 such that a peripheral portion 26
remains joined to the side wall 20, and projects radially inwardly
therefrom. Alternative container bodies may remove the panel 12
from any portion of the container body, such as the side wall 20,
to list a non-limiting example, or may remove the entire end wall
such that no peripheral portion 26 remains joined to the side wall
20. The resulting panel 12 defines an outer edge 14 of the panel.
The opening 36 defines an inner edge 24 of the end wall 22 that
encircles the opening.
[0028] As seen in FIG. 7, the cut line is made at a 45 degree angle
and tapers inward as it progresses toward the interior of the end
wall 22 such that the panel 12 may be removed from the exterior of
the container body 10. Alternatively, the cut angle may range
between 0 and 90 degrees if the panel 12 is to be removed from the
exterior of the container body 10 or may range between 90 and 180
degrees if the panel is to be removed toward the interior of the
container body. A 90 degree cut allows the panel 12 to be removed
toward either the exterior or interior. Any cutting or perforating
method may be utilized to separate the panel 12 from the wall of
the container body 10. Preferably little or no material is removed
from the container body 10 and panel 12 during the cutting process
so that the panel 12 substantially completely covers or fills the
opening 36, such that the outer edge 14 of the panel is closely
adjacent the inner edge 24 of the container body 10.
[0029] A pull feature, such as the combined pull tab 30 and ring 32
of FIG. 4, may be added to the panel 12. The pull feature
facilitates removal of the panel 12 from the container body 10
after the panel has been reattached to the container body 10. The
pull feature provides a surface that can be gripped to pull the
panel 12 away from the container body 10. Alternatively the pull
feature may comprise only a pull tab 30 or may comprise a
protrusion on the exterior surface 18 of the panel 12 formed when
the container body 10 was formed. The protrusion may provide a
convenient surface for an individual to pull the panel 12 from the
container body 10. If the pull feature is joined to the panel 12
during a process subsequent to the forming of the container body
10, the joining process may include conductive heat sealing,
ultrasonic sealing, heat staking, the applying of adhesives, or any
other joining method.
[0030] The pull feature of FIG. 4 is a single component consisting
of a pull tab 30 and a ring 32, wherein the pull tab is connected
to the ring and the ring is joined to the exterior surface 18 of
the panel 12. The ring 32 of FIG. 4 is joined along the perimeter
of the panel 12 and overhangs the outer edge 14 of the panel 12.
This configuration provides an overhanging portion of the ring 32
that may subsequently be used to form a sealed, frangible interface
with a portion of the container body 10. The ring 32 may
alternatively be joined to the outer edge 14 of the panel 12, or
may be joined to any surface of the panel. Furthermore, the ring
may completely encircle the panel 12, or the ring may only
partially encircle the panel, such as with a 90 degree arc or a 180
degree arc, to list two non-limiting examples.
[0031] The pull feature of FIG. 4 is joined to the panel 12 after
the panel has been cut from the container body 10 and before the
panel is reattached to the container body. Alternatively, the
panels may include a pull feature joined before or during the
cutting of the panel or joined during or after the reattaching of
the panel. The pull feature may be of any suitable material such as
a polymer, elastomer, or elastomeric polymer, to list non-limiting
examples. The pull feature preferably can withstand harsh
manufacturing processes while maintaining the structural strength
to facilitate subsequent removal of the panel 12 from the container
body 10.
[0032] FIG. 5 shows the panel 12 reattached to the container body
10, and FIG. 6 shows the panel being removed from the container
body. The panel 12 of FIG. 5 is reattached with a sealed, frangible
interface 34, as illustrated in FIG. 7, created by the engagement
of the overhanging portion of the ring 32 and the peripheral
portion 26 of the container body 10. The sealed, frangible
interface 34 provides a hermetic seal that prevents the
transmission of oxygen, moisture, contaminants, and other
substances into or out of the container. Furthermore, the sealed,
frangible interface 34 provides a separation surface for the panel
12 from the container body 10 because the bond strength between the
overhanging portion of the ring 32 and the peripheral portion 26 of
the container body is not as strong as the bond strength between
the ring and the panel. Therefore, pulling the pull tab 30 of the
pull feature, as illustrated in FIG. 6, separates the panel 12 from
the container body 10 along the sealed, frangible interface 34
rather than removing the pull feature from the panel. FIG. 6 shows
the panel 12 partially removed, and further pulling on the pull tab
30 may completely remove the panel from the container body 10. The
panel 12 may bend an amount less than, equal to, or greater than
the bending of the panel shown in FIG. 6, as the amount of bending
depends upon the thickness and material of the panel and the bond
strength of the sealed, frangible interface 34.
[0033] An alternative sealed, frangible interface 134 is shown in
FIG. 8. The pull feature is joined to the panel such that the ring
132 is joined to the outer edge of the panel 12 with an interface
136 and the pull tab projects above the exterior surface 18 of the
panel. The interface 136 does create a seal similar to the seal,
frangible interface 134, but is not frangible during the ordinary
use of the container. The sealed, frangible interface 134 of FIG. 8
is created between the surface of the ring 132 opposite the outer
edge 14 of the panel 12 and the inner edge 24 of the peripheral
portion 26 of the container body 10'. Such engagement between the
surface of the ring 132 and the inner edge 24 may include the
addition of a bonding material or may involve a manufacturing
process to create the sealed, frangible interface 134.
[0034] The sealed, frangible interface, such as the interface 34 of
FIG. 7, the interface 134 of FIG. 8, or the interfaces of other
embodiments, may include an adhesive or other joining compositions.
Non-limiting examples of materials that may be applied to create
the sealed, frangible interface are epoxies and heat set adhesives.
Alternatively, the sealed, frangible interface may be created by a
manufacturing process without the application of additional
materials. One non-limiting example is a heat staking process using
conductive, inductive, or ultra sonic methods. Regardless of the
method used to create the sealed, frangible interface, the bond
strength of the sealed, frangible interface is less than the bond
strength between the joined pull feature and panel. The sealed,
frangible interface is preferably configured such that once the
panel 12 has been removed, the inner edge 24 of the peripheral
portion 26 does not include any surface defects that might
interfere with removal of the contents or that might inconvenience
the consumer.
[0035] FIG. 9 shows a panel 12 reattached to the container body 10"
by heat staking to form a sealed, frangible interface 334. The pull
feature of FIG. 9 does not include a ring, such as a ring 32 of
FIG. 7; therefore, the panel 12 is reattached directly to the
peripheral portion 26 of the container body 10. As shown in FIG. 9,
the heat staking process essentially melts the material proximate
the outer edge 14 of the panel 12 and the inner edge 24 of the
peripheral portion 26 of the container body 10" so that the panel
is reattached to the container body. A non-limiting example of a
heat staking process is the use of RF generation wherein the
electrodes are positioned adjacent the outer edge 14 and inner edge
24 to create a radio frequency field, preferably in the range of
0.1 to 300 MHz, that melts the material comprising the outer edge
and inner edge, which is preferably a heatable polymer or
thermoplastic, thus creating the sealed, frangible interface 334;
as known in the art, the RF process requires some type of
electrically conductive material in the polymer. Alternative
processes and materials may be used to create the sealed, frangible
interface 334. Thus the sealed, frangible interface 334 of FIG. 9
reattaches the panel 12 and container body 10" along the cut line
preferably with a bond strength less than the internal bond
strength of the end wall 22 prior to cutting or with a
configuration to facilitate subsequent removal of the panel from
the container body along the sealed, frangible interface 334. A
non-limiting example of a configuration to facilitate removal of
the panel 12 is an interface that creates a stress concentration
and to initiate and propagate the separation of the panel from the
container body 10. Regardless of the method of reattaching utilized
or the configuration of the panel, pull feature, and sealed,
frangible interface, the panel 12 is reattached to the container
body 10" to seal the container and to provide a convenient method
of opening the container.
[0036] The panel 12 may alternatively be made separately from the
container body 10, such that the opening 36 of the container of
FIG. 4 was created during the forming of the container body. The
container body 10 is formed with an opening 36 defining the inner
edge 24 of the end wall and the panel 12 is sized to substantially
completely cover the opening to create a sealed, frangible
interface between the panel and container body when the panel is
attached to the container body. The separately made panel 12 may
include a pull feature and/or may be attached by methods similar to
those of the containers that include a panel cut from the container
body 10.
[0037] The container body 10 may also include a second opening 38,
as shown in FIGS. 2-5, defined by an opposite end 28 of the side
wall 20. This second opening 38 is preferably included to allow the
insertion of the contained product into the container body. FIG. 7
illustrates a product 50 contained within the container body 10
that is enclosed by a closure 40 attached to the opposite end 28 of
the side wall 20. The contained product 50 is preferably inserted
into the container body 10 after the panel 12 has been cut and
reattached, or simply attached, and the sealed, frangible interface
34 has been created. After the contained product 50 has been
inserted into the container body 10, a closure 40 is attached to
the opposite end 28 of the side wall 20. The closure 40 is not
intended to be removed by a consumer; rather, the panel 12 with the
pull feature is intended to be removed by a consumer to gain access
to the contents through the opening 36. Alternatively, other
container bodies may not include a second opening 38 and closure,
wherein the product 50 is inserted into the container body 10 prior
to the reattachment of the panel 12, or the container bodies may
not insert the product through the second opening 38 though one is
provided.
[0038] Many containers manufactured with thermoforming, blow
molding, or similar forming processes necessarily include an
opening because of the mechanical limitations of the manufacturing
process. The second opening 38 defined by the opposite end 28 of
the side wall 20 of the FIG. 7 is an example of an opening created
during forming. Often the opening created during forming is not the
preferred opening for the consumer to gain access to the contents
within the container. The present invention addresses this
situation by cutting the panel 12 from the container and
reattaching the panel to create an opening 36 for consumers to gain
access to the product 50 while sealing the originally formed second
opening 38 and preventing access to the product through the second
opening. Alternatively, the container may be formed with multiple
second openings or may be formed with no second opening. If a
second opening is included in the container body, a closure may be
attached to seal the product within the container.
[0039] Containers formed by thermoforming include an opening at the
largest end of the container so that the container body can be
removed from the thermoforming equipment. Because thermoforming
equipment typically includes a single mold into which the raw
material is formed, the formed item must not include any portions
within the mold that are larger than the opening of the mold.
Therefore, thermoformed items typically include an opening at the
largest portion of the item. The present invention overcomes this
constraint by providing a thermoformed container body 10 that
defines a top of the container and a bottom end of the container.
An opening 36 illustrated in FIG. 4 is provided in the top end of
the container body 10, which coincides with the end wall 22. The
container body 10 flares outwardly from the top end to the bottom
end. The opposite end 28 of side wall 20 functions as the bottom
end of the container body 10. By cutting the panel 12, an opening
36 is provided on the top of the thermoformed container body. The
panel 12 functions as a removable lid after it is reattached to the
container body 10 to create the sealed, frangible interface. The
opening formed while thermoforming the container body 10 is the
second opening 38 that is subsequently covered by a closure.
[0040] The container body 10 of FIG. 7 includes a closure that is a
film membrane 40. Preferably the film membrane 40 is a foil
membrane with an upper polymer layer 44 and a lower foil layer 42
that provides convenient attachment to the opposite end 28 of the
side wall 20 and that prevents the transmission of oxygen,
moisture, and other substances through the membrane. After the
product 50 has been inserted into the container body 10, the
membrane 40 is positioned over the second opening 38, thus engaging
the entire opposite end 28, and is attached to the opposite end
using adhesive materials or manufacturing processes to create a
seal. The foil membrane 40 of FIG. 7 is attached by conductively
heating the upper polymer layer 44 along the opposite end 28 of the
polymer container body 10 such that a bond is created. The foil
membrane 40 thus defines the bottom of the container body 10 of
FIG. 7 and the panel 12 defines the top of the container
[0041] An alternative closure for the second opening 38 of
container body 10' is shown in FIG. 8. The closure of FIG. 8 is a
metal end 240 double seamed to the opposite end 228. The opposite
end 228 includes a flange 230 that encircles the opposite end and
that projects outward from the opposite end. The flange 230 of FIG.
8 facilitates the attaching of the metal end 240 by a double seam
process. U.S. Pat. No. 5,971,259 to Bacon discloses a method of
double seaming metal ends to containers, the disclosure of which is
incorporated herein. The metal end 240 is positioned over the
second opening 38 thus engaging the entire opposite end 28 and is
rolled and tucked about the flange 230 to attach the metal end and
to create a seal that prevents the transmission of oxygen,
moisture, and other substances through the interface between the
metal end and flange 230. Compound materials may be included on the
flange 230 or the portion of the metal end 240 engaging the flange
to assist in the sealing of the metal end by filling any gaps
created during the double seaming process.
[0042] Yet another alternative closure for the second opening 38 of
container body 10" is shown in FIG. 9. The closure of FIG. 9 is a
cover 440 of the same material as the container body 10".
Therefore, if the container body 10" is a polymer material, to name
a non-limiting example, then the cover 440 is the same polymer
material. Providing the same material cover allows the cover to be
attached to the opposite end 428 by a heat staking process to
create a sealed interface 446. The heat staking process may be the
same or similar heat staking process used to create the sealed,
frangible interface 334 of FIG. 9. The material of the upper
surface 444 of the cover is heated along with the material of the
opposite end 428 such that the materials unite and when cooled
create the sealed interface 446. Similar to the closures of FIG. 7
and FIG. 8, the cover 440 of FIG. 9 defines the bottom surface of
the container body 10". Alternative closures for second openings
may be used for additional containers of the present invention. In
addition, the various pull features and reattachment configurations
for the panel 12 may be combined with the various closures and
attachment configurations for the closures to define additional
embodiments of the present invention.
[0043] A further embodiment of the container is illustrated in FIG.
10, wherein the pull feature is a pull tab 30 without a ring, such
as the ring 32 shown in FIG. 4. The pull tab 30 of FIG. 10 is
attached to the exterior surface 18 of the panel 12. The pull tab
30 may be joined to the panel 12 before cutting the panel, before
reattaching the panel, or after reattaching the panel. The pull tab
30 of FIG. 10 may also be joined to the panel 12 by any of the
processes used to attach the pull feature of FIGS. 1-6.
[0044] Many modifications and other embodiments of the invention
set forth herein will come to mind to one skilled in the art to
which the invention pertains having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the invention is
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *