U.S. patent application number 11/062967 was filed with the patent office on 2005-09-15 for packaging container and blank for producing the same.
Invention is credited to MacConkey, James S., Masie, Dennis J..
Application Number | 20050199696 11/062967 |
Document ID | / |
Family ID | 34922079 |
Filed Date | 2005-09-15 |
United States Patent
Application |
20050199696 |
Kind Code |
A1 |
MacConkey, James S. ; et
al. |
September 15, 2005 |
Packaging container and blank for producing the same
Abstract
A packaging container that is made from a flat sheet of material
or extruded material with score lines that fold into a plurality of
side panels, 3 or more, forming a tubular member having a
longitudinal axis. The bottom folds concave and the top folds
convex forming triangular webs having apexes which join at the
longitudinal axis with the side edges of the adjacent triangular
webs sealed together providing structural rigidity. The webs fold
inside or outside and the scores can be such that a plurality of
variations can be created for different appearances of the
container. Protrusions extend outward from the apex of at least
some of the top and bottom web panels which provide a means for
sealing. Flaps on the ends of the side panels fold and seal
together either to the inside or outside. The container can be
stacked and nested.
Inventors: |
MacConkey, James S.;
(Thousand Oaks, CA) ; Masie, Dennis J.; (Agoura
Hills, CA) |
Correspondence
Address: |
Dennis J. Masie
#144
5699 Kanan Road
Agoura Hills
CA
91301
US
|
Family ID: |
34922079 |
Appl. No.: |
11/062967 |
Filed: |
February 22, 2005 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60547081 |
Feb 25, 2004 |
|
|
|
Current U.S.
Class: |
229/249 ;
229/117.13; 229/125.15; 229/137; 229/138 |
Current CPC
Class: |
B65D 5/46096 20130101;
B65D 15/22 20130101; B65D 5/029 20130101; B65D 5/727 20130101 |
Class at
Publication: |
229/249 ;
229/125.15; 229/137; 229/138; 229/117.13 |
International
Class: |
B65D 005/46; B65D
043/00; B65D 005/08; B65D 005/72 |
Claims
What is claimed is:
1. A container comprising: (a) a plurality of flat side panel
portions each having a top and bottom and defining a tubular member
having a longitudinal axis and a polygonal cross section; (b) a top
closure formed by a first plurality of triangular shaped panels
each having a base, two sides and an apex and each of which is
formed integrally with the top of one of said side panel portions,
each of said triangular shaped panels being defined by score lines
extending angularly downwardly from the apex at the top of said
tubular member to a first transverse score line disposed displaced
from said top and forming the base, each of said triangular shaped
panels being folded inwardly so that their apexes join
substantially at said axis and so that sides of adjacent panels of
said first plurality of triangular shaped panels engage each other;
(c) means for sealing said sides of said adjacent triangular shaped
panels of said first plurality of triangular shaped panels
together; (d) a bottom closure formed by a second plurality of
triangular shaped panels each having a base, two sides and an apex
and each of which is formed integrally with the bottom of one of
said side panel portions, each of said triangular shaped panels
being defined by score lines extending angularly upwardly from the
apex at the bottom of said tubular member to a second transverse
score line disposed displaced from said bottom and forming the
base, each of said triangular shaped panels being folded inwardly
so that their apexes join substantially at said axis and so that
sides of adjacent panels of said second plurality of triangular
shaped panels engage each other; and (e) means for sealing said
sides of said adjacent triangular shaped panels of said second
plurality of triangular shaped panels together.
2. A container as defined in claim 1 wherein said second plurality
of triangular shaped panels are disposed with their apexes located
internally of said tubular member thereby providing a substantially
concave bottom closure.
3. A container as defined in claim 1 which further includes an
additional triangular shaped panel having two sides, a base and an
apex disposed between adjacent ones of said first and second
plurality of triangular shaped panels, one side of said additional
triangular shaped panel being common with a side of an adjacent one
of said plurality of triangular shaped panels.
4. A container as defined in claim 3 wherein each said additional
triangular shaped panel includes a score line extending from its
apex and extending to a right angle intersection with its base to
allow said additional triangular shaped panel to fold against
itself to provide a supporting web for said closure.
5. A container as defined in claim 4 wherein said supporting webs
are disposed internally of said tubular member.
6. A container as defined in claim 4 wherein said supporting webs
are disposed externally of said tubular member.
7. A container as defined in claim 1 which further includes a
protrusion extending outwardly from the apex of at least some of
said triangular shaped panels on said top closure and said bottom
closure and means for sealing said protrusions together to form a
fillet for sealing said top and bottom closures.
8. A container as defined in claim 7 wherein said second plurality
of triangular shaped panels are disposed with their apexes located
internally of said tubular member thereby providing a substantially
concave bottom closure.
9. A container as defined in claim 7 which further includes an
additional triangular shaped panel having two sides, a base and an
apex disposed between adjacent ones of said first and second
plurality of triangular shaped panels, one side of said additional
triangular shaped panel being common with a side of an adjacent one
of said plurality of triangular shaped panels.
10. A container as defined in claim 9 wherein each said additional
triangular shaped panel includes a score line extending from its
apex and extending to a right angle intersection with its base to
allow said additional triangular shaped panel to fold against
itself to provide a supporting web for said closure.
11. A container as defined in claim 1 which is formed from a flat
sheet of material having score lines extending between at least
said top and bottom closures to define said flat panels portions
and to permit said flat sheet to be folded about said score lines
to form said tubular member.
12. A container as defined in claim 11 wherein said flat sheet of
material includes a flap extending substantially along each side
edge thereof, said flaps being sealed together when said sheet is
folded about said score lines to form said tubular member.
13. A container as defined in claim 12 wherein said flaps extend
externally of said tubular member and provide a handle for
manipulation of said container.
14. A container as defined in claim 4 wherein said first, second
and additional plurality of triangular shaped panels are all
equilateral triangles.
15. A container as defined in claim 4 wherein said first plurality
of triangular shaped panels and said additional triangular shaped
panels disposed therebetween are isoseles triangles.
16. A container as defined in claim 15 wherein said sides of said
first additional plurality of triangular shaped panels are longer
than the bases thereof so that said top closure extends upwardly to
form a bottle type of container.
17. A container as defined in claim 16 wherein said supporting webs
are disposed externally of said tubular member.
18. A container as defined in claim 16 wherein said supporting webs
are designed internally of said tubular member.
19. A container as defined in claim 1 wherein said tubular member
is formed from an extruded tube.
20. A container as defined in claim 11 wherein said flat sheet of
material comprises a plurality of sheets of material laminated
together.
21. A container as defined in claim 20 wherein said laminate
includes an inner layer of food grade material, an outer layer and
a stiffener layer sandwiched between said inner and outer
layers.
22. A container as defined in claim 21 which further includes an
additional triangular shaped panel having two sides, a base and an
apex disposed between adjacent ones of said first and second
plurality of triangular shaped panels, one side of said additional
triangular shaped panel being common with a side of an adjacent one
of said plurality of triangular shaped panels, said additional
triangular shaped panel being formed only on said inner layer of
material.
23. A container as defined in claim 22 wherein each said additional
triangular shaped panel includes a score line extending from its
apex and extending to a right angle intersection with its base to
allow said additional triangular shaped panel to fold against
itself to provide a supporting web for said closure.
24. A container as defined in claim 23 which further includes a
protrusion extending outwardly from the apex of at least some of
said triangular shaped panels on said top closure and said bottom
closure and means for sealing said protrusions together to form a
fillet for sealing said top and bottom closures, said protrusions
being only on said inner layer of material.
25. A container as defined in claim 4 wherein one of said first
plurality of triangular shaped panels is adopted for use as a
dispensing spout and said additional triangular shaped panel on
each side of said dispensing spout panel is disposed externally of
said tubular member and is folded over said dispensing spout
panel.
26. A container as defined in claim 25 wherein each of said
additional triangular shaped panels on each side of said dispensing
spout panel further includes a tab member extending therefrom for
use in placing said dispensing spout panel in a position to
dispense contents of said container.
27. A container as defined in claim 1 which is formed from an
extruded tubular member having score lines defining said first and
second plurality of triangular shaped panels.
28. A container as defined in claim 1 wherein one of said first
plurality of triangular shaped panels defines a plurality of
openings therethrough.
29. A container as defined in claim 28 wherein said additional
triangular shaped panel on each side of said panel defining
openings therethrough is disposed externally of said container and
is folded over said panel defining openings therethrough.
30. A container comprising: (a) a plurality of flat side panel
portions each having a top and bottom and defining a tubular member
having a longitudinal axis; (b) a top closure formed by a first
plurality of generally triangular shaped panels each having a base,
and each of which is formed integrally with the top of one of said
side panel portions, the sides of each of said generally triangular
shaped panels being defined by score lines extending angularly
downwardly to a first transverse score line disposed displaced from
said top and forming the base, each of said triangular shaped
panels being folded inwardly so that sides of adjacent panels of
said first plurality of triangular shaped panels engage each other;
(c) means for sealing said sides of said adjacent triangular shaped
panels of said first plurality of triangular shaped panels
together; (d) a bottom closure formed by a second plurality of
triangular shaped panels each having a base, two sides and an apex
and each of which is formed integrally with the bottom of one of
said side panel portions, each of said triangular shaped panels
being defined by score lines extending angularly upwardly from the
apex at the bottom of said tubular member to a second transverse
score line disposed displaced from said bottom and forming the
base, each of said triangular shaped panels being folded inwardly
so that their apexes join substantially at said axis and so that
sides of adjacent panels of said second plurality of triangular
shaped panels engage each other; and (e) means for sealing said
sides of said adjacent triangular shaped panels of said second
plurality of triangular shaped panels together.
31. A container as defined in claim 30 wherein said score lines
forming said sides of each said generally triangular shaped panel
extend in a substantially parallel spaced apart manner from a third
transverse score line disposed between said first transverse score
line and said top to said top.
32. A container as defined in claim 31 which further includes a web
member disposed between adjacent ones of said generally triangular
shaped panels and extending externally of said tubular member, each
said web member being folded over to engage an adjacent panel
member and being sealed thereto.
33. A blank for packaging containers, said blank comprising a flat
sheet of material having upper and lower transverse score lines
corresponding substantially to the top and bottom of the container
and having a plurality of side wall panels, the side wall panels
being designed by pairs of parallel vertical score lines
intersecting said first and second transverse score lines a first
plurality of diagonally disposed score lines extending between said
first transverse score line and the top of said sheet of material
and a second plurality of diagonal score lines extending between
said second transverse score line and the other end of said sheet
of material, said blank being adapted to form a container.
34. A blank as defined in claim 33, which further includes
additional score lines displaced from said side edges of said sheet
of material to form side flaps to be sealed together in forming
said container.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to packaging containers formed
from flat sheets of material or extruded materials that are
provided with appropriate score lines to facilitate conversion of
the packaging material into individual sealed packaging containers
and to blanks or packaging material from which the packaging
containers are formed.
BACKGROUND OF THE INVENTION
[0002] Consumer packages intended for single use and containing
consumer products of various types including both dry goods and
beverages are normally produced from packaging material comprising
layers of paper, cardboard, plastic, foil or the like. When
consumable food products are housed in the containers they are
coated with a food grade material. Such materials may be laminated
if desired to provide additional strength. The containers housing
liquids also include liquid tight seals which are normally realized
by heat sealing or appropriate adhesives. The prior art contains
examples of various types of such packaging containers and some
take the form of either a parallelepipedic or a gable-top type of
structure. Each of these packaging containers generally include
four vertical wall panels or side walls with top and bottom walls
which provide an appropriate closure for the containers.
[0003] These conventional packages in use are grasped at the side
walls by the consumer for opening and dispensing of the contents
contained therein. By so doing, it is possible that the side walls
will be pressed together more than is desirable and to avoid this
the package should be manufactured from a relatively thick
packaging laminate. To avoid this problem, attempts have been made
to construct packaging containers having a hexagonal cross-section,
which provides greater strength and handling capabilities. However,
it has been found that the sealing of the top and bottom of such
containers to obtain a liquid-tight seal is, in most instances,
difficult.
[0004] Additional types of packages for containing such materials,
particularly liquids, include pouches made from foil material which
is sealed to provide an appropriate air tight and water tight seal
to prevent leakage of the liquid contained therein. Such foils are
however very difficult to handle both by the merchant and by the
user. An additional problem which is encountered with all of the
prior art type of packaging for such consumables is the difficulty
in transporting the packages, and storing the packages, as well as
stacking and shelf space limitations encountered as a result of the
configuration of the package.
[0005] There is thus a need in the packaging industry, particularly
as it relates to single use nonreturnable packages for containing
dry goods as well as wet goods, to provide a package which can be
easily manufactured utilizing fully automatic packaging machines
and which at the same time requires a minimum of space and can be
easily shipped, stored and stacked. Such packages should also be
capable of being manufactured from any material presently being
utilized such as foil, paper, cardboard and plastic materials both
single layer and laminated.
SUMMARY OF THE INVENTION
[0006] A container having a plurality of flat side panel portions
each having a top and a bottom and defining a tubular member having
a longitudinal axis. Top and bottom closures are formed by a
plurality of triangular shaped panels each of which is formed
integrally with the flat side panel portions disposed in such a
manner that each of the triangular shaped panels when folded
inwardly have apexes which join substantially at the longitudinal
axis with the side edges of adjacent triangular shaped panels
sealed together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a plan view of a blank from which a container
constructed in accordance with the principles of the present
invention is constructed;
[0008] FIG. 2 is a perspective view of a tube formed by folding the
blank as shown in FIG. 1 along appropriate score lines;
[0009] FIG. 3 is a side view illustrating the container of the
present invention with the top closure formed;
[0010] FIG. 4 is a perspective view showing the bottom closure of
the present invention;
[0011] FIG. 5 is a side view showing a pair of containers formed in
accordance with the present invention stacked one upon the
other;
[0012] FIG. 6 is a side view showing a plurality of containers
constructed in accordance with the present invention stacked upon a
transport mechanism;
[0013] FIG. 7 is a partial view showing a laminate from which a
container in accordance with the present invention may be
constructed;
[0014] FIG. 8 is a partial plan view showing a top portion of a
blank constructed from the laminate of FIG. 7.
[0015] FIG. 9-A is a plan view of a blank from which a container
constructed in accordance with the principles of the present
invention may be constructed and which container includes a spout
as part of the final product;
[0016] FIGS. 9-B, 9-C and 9-D illustrate a container top
constructed from the blank of FIG. 9-A in its closed, partially
open and fully open positions respectively;
[0017] FIG. 10 is a plan view of a blank from which a container
constructed in accordance with the principles of the present
invention may be constructed and which includes a handle
mechanism;
[0018] FIG. 11 is a perspective view showing one form of a
container constructed in accordance with the principles of the
present invention which may be collapsed into a flat position for
shipping and which also includes an accessory spout and cap;
[0019] FIG. 12 is a perspective view of an extruded tubular member
from which a container constructed in accordance with the
principles of the present invention may be constructed;
[0020] FIG. 13 illustrates an alternative package which provides
the ability to drain liquid from contents packaged within the
container independently of removing the contents from the
container;
[0021] FIG. 14 is a partial plan view of a blank from which the
container of FIG. 14 can be constructed;
[0022] FIG. 15 is a perspective view of a container constructed in
accordance with the present invention and which includes an
elongated upper portion providing a bottle shaped container;
[0023] FIG. 16 is a perspective view of a container constructed in
accordance with present invention which is in the form of a
traditional bottle for holding red wine;
[0024] FIG. 17 is a plan view of a blank form which the bottle of
FIG. 16 is constructed;
[0025] FIG. 18 is a perspective view illustrating one form of
closure for a bottle-shaped container constructed in accordance
with the present invention;
[0026] FIG. 19 is similar to FIG. 18 but with an alternative type
of closure; and
[0027] FIGS. 20-22 illustrate a container similar to that shown in
FIG. 3 but with three different dispensing closures incorporated
therein.
DETAILED DESCRIPTION
[0028] The preferred embodiments of the packaging container
according to the principles of the present invention and as shown
in the drawings are manufactured from a blank of material, such as
Polyethylene Terephthalate (PET), which is approved for use with
food and beverage. Alternatively, the container may be manufactured
from a packaging laminate which comprises a core layer of material
such as paper, foil, cardboard, chipboard, flute board, corrugated
board or the like, which is coated on either or both sides with
thin layers of thermoplastic material, for example, polyethylene
and may also include high-density polyethylene. Depending upon the
product being housed and the particular packaging laminate used,
the blank may also include further layers of barrier material, for
example, aluminum foil.
[0029] The packaging container, according to the principles of the
present invention, is substantially of a form which includes a
plurality of sides, three or more, and may be pyramidal,
rectangular, pentagonal, hexagonal, octagonal or the like in form.
In addition to the side surfaces, there are top and bottom closures
for the container which are formed integrally with the side panels
or surfaces and which preferably fold into a substantially convex
top closure and a concave bottom closure which permits the packages
to be readily stacked, one upon the other, however, other shapes to
the top and bottom closures may be used without departing from the
shape of the present invention.
[0030] The side wall or panel portions can be divided into a number
of panels by means of a desired score or crease line pattern so as
to create a plurality of variations in the basic form of the
packaging container in terms of appearance. For example, the
container may be a symmetric, tubular structure having a plurality
of equal area side panels terminating at the top and bottom in the
desired closures as referred to above. However, the container may
be constructed in such a matter as to have sloping or contoured
sides to provide a container having the overall general appearance
of a bottle.
[0031] According to a primary principle of the present invention,
the top and bottom closures are formed integrally with the side
panels by providing crease or score lines adjacent to the top and
bottom of the structure forming the side panels so as to provide a
plurality of triangular-shaped panels which may be folded inwardly
so that the apexes of the triangular-shaped panels join
substantially at the longitudinal axis of the container and may
then be sealed along their adjacent edges to provide an air tight
and water tight closure for the top and bottom of the container
where such is required.
[0032] Referring now more particularly to FIG. 1, there is
illustrated a blank 10 of material such as for example as a flat
sheet of Polyethylene Terephthalate from which a container
constructed in accordance with the principles of the present
invention may be formed. The blank 10 is a sheet 12 of material
which is provided with a plurality of crease or score lines 14
through 22 defining a plurality of flat panels as shown at 24
through 34, respectively. The sheet of material 12 has an upper end
36 and a lower end 38. Displaced from the upper end 36 is a
transversely disposed score line 40 while displaced from the lower
end 38 is a transversely disposed score line 42. The top and bottom
closures are formed from the material on the sheet 12 defined
between the upper edge 36 and the score line 40 for the top and the
lower edge 38 and the score line 42 for the bottom, respectively.
The upper or top closure is formed from a plurality of
triangular-shaped panels 44 through 54. These triangular-shaped
panels are defined by score lines extending from the transverse
score line 40, which forms the base for each of the
triangular-shaped panels 44 through 54, and extending upwardly to
the apex of each of the triangular-shaped panels 44 through 54 as
shown at 56 through 68, respectively. Thus, it can be seen that
each of the triangular-shaped panels has a base, two sides and an
apex. A protrusion extends outwardly from each of the apexes 56
through 68 as illustrated at 70 through 80, respectively. As will
be described more fully below when the container is formed from the
blank 10 these protrusions form a seal for the top closure. Each of
the triangular-shaped panels 44 through 54 are folded inwardly in
such a manner that their apexes join substantially at a
longitudinal axis 122 (FIG. 2) defined by the container. The
protrusions 70 through 80 are sealed together to provide a
liquid-tight and airtight seal for the top closure of the container
formed from the blank 10. As is also illustrated in FIG. 1, there
is provided an additional triangular-shaped panel or web as shown
at 82 through 92, which web is defined by the same score lines that
define the triangular-shaped panels 44 through 54. Each of the
additional panels or webs also include a score or crease line which
bisects the web from its apex to its base, which base is defined by
the outer edge 36 of the sheet of material 12. These additional
score lines are formed on the opposite surface from that viewed in
FIG. 1 and are indicated by the dash lines 94 through 102. An
additional score line is provided for the additional
triangular-shaped panel or web 92 as shown at 104 and which will be
described in more detail hereinbelow. The score lines 94 through
104 allow the additional panels or webs 82 through 92 to be folded
into the interior of the container formed from the blank 10 as
shown in FIG. 1. When such is done, the side edges of adjacent
triangular-shaped panels 44 through 54 abut or engage each other as
do the two halves of each of the webs which may be sealed together
to secure the closure structure and ensure its structural integrity
as will be described more fully below. The score lines 94 through
104 may be on the opposite surface from that shown, that is, they
may be on the same surface as the score lines 14 through 22, thus
allowing the additional panels or webs to extend on the outside of
the container when the triangular-shaped panels are folded inwardly
to form the closure. Again, the two halves of each of the webs will
engage each other and may be sealed together.
[0033] The bottom closure is formed by a plurality of
triangular-shaped panels, each of which has a base, two sides and
an apex and is formed integrally with the sheet 12 from the
material in the area disposed between the lower edge 38 thereof and
the transverse score line 42. Disposed between each of the
triangular-shaped panels and the lower edge 38 is also an
additional triangular-shaped panel or web which shares the sides of
the adjacent triangular-shaped panels and has a bisecting score
line from the apex to the base thereof. There is also provided a
protrusion extending outwardly from the apex of each of the
triangular-shaped panels which meet substantially at the
longitudinal axis 122 of the container formed from the blank 10 and
are sealed to provide a bottom closure which is airtight and
liquid-tight. The score lines and structure forming the bottom
closure is substantially identical to that described above with
respect to the top closure and such is indicated by utilizing the
same reference numerals primed as were used for the structure of
the top closure. It should be noted that the triangular-shaped
panels 44 through 54 and 44' through 54' are formed at the top and
bottom extensions of the flat side panel portions 24 through 34,
respectively, and are thus formed integrally with the flat sheet
12.
[0034] An additional score line 106 is displaced from the side edge
108 of the sheet 12. The area of the sheet 12 between the score
lines 106 and 104 and the outer edges 108 and 112 respectively are
provided to form a pair of flaps 114 and 116 which will be folded
inwardly into the interior of the container and are sealed together
along their contacting surfaces to provide a sealed tubular member
which is used to form the container from the blank 10. It will also
be recognized that the score lines 104 and 106 also extend to
bisect the webs 92 through 92' from the apexes thereof the
respective bases.
[0035] The blank 10 as above described is formed by die cutting
from a continuous sheet or strip of plastic material. As above
pointed out, the sheet of material may also be a laminate structure
depending upon the particular product to be housed therein,
however, the use of the crease or score lines as above described to
form the tubular member and the top and bottom closures remains
equally applicable.
[0036] Referring now more particularly to FIGS. 2 and 3 there is
illustrated the formation of a container from the blank 10 as
illustrated in FIG. 1 and above described. FIG. 2 illustrates the
blank 10 which has been rolled into a tubular form with the flaps
114 and 116 disposed internally thereof. Flaps 114 and 116 have
been sealed together along their mating or engaging surfaces to
produce the generally tubular form shown in FIG. 2. The sealing of
the flaps 114 and 116 together provide an air tight and water tight
seal for the edge of the container. The sealing is preferably
accomplished through the utilization of an ultrasonic welding head
when a thermoplastic material is used for the sheet 12. Such an
ultrasonic welding head is well known to those skilled in the art
and to accomplish the desired weld, it has been found that the
highest frequency available for the ultrasonic weld head should be
utilized. It should however be recognized that with thermoplastic
materials of the type above referred to, an appropriate seal may be
accomplished through the application of heat and pressure to the
flaps 114 and 116 causing them to fusion weld together. Similarly,
radio frequency energy may be applied from an appropriate generator
of such to also accomplish an effective seal. It will also be
recognized by those skilled in the art that depending upon the
material used and the application for the container, sealing may be
accomplished by an appropriate adhesive.
[0037] It should be recognized by those skilled in the art that
automatic machinery known as erection stations will be utilized to
produce the container into the tubular form as shown in FIG. 2. The
erection stations will also be utilized to automatically form the
top and bottom closures. In producing the top closure, the webs
82-92 will be pushed inwardly into the interior of the tubular
member while at the same time, the triangular shaped panels 44-54
will be folded inwardly into the interior of the tubular member so
that the apexes of each of the triangular shaped panels will join
substantially at the longitudinal axis of the tubular member as
shown in FIG. 2. When such has been accomplished, the side edges of
adjacent triangular shaped panels are sealed together to form the
integrated top closure. For example, as shown in FIG. 3, the side
edges of the triangular shape panel 44 which adjoin the side edge
of the triangular shaped panel 46 and the triangular shape panel 54
are welded together to provide a welded seam as shown at 118 and
120. Similarly, the adjacent or adjoining side edges of the
remaining triangular shaped panels are also sealed so that a
completed convex shaped top closure is produced. The sealing, as
was the case with the flaps 114 and 116 is accomplished by
ultrasonic welding through the technique of placing the mandrel
portion of the head internally of the cylinder and the ultrasonic
horn externally of the cylinder thus formed which upon activation
accomplishes the sealing. Again, alternative methods of
accomplishing the seal which preferably is air tight and water
tight as above described may be utilized if desired. It has been
found that when the triangular shaped panels are positioned
together and sealed along their adjacent sides as above described,
there remains a pin hole at the apexes of the triangle. The
protrusions 70-80 adjacent each of the apexes 56-66 of the
triangular shaped panels 44-54, respectively, meet at the
longitudinal axis 122 of the cylinder and are then also sealed
together as by ultrasonic welding. Such ultrasonic welding then
closes the pinhole and totally seals the top closure and provides
an air tight and water tight seal to that portion of the container.
As is also shown particularly in FIG. 3, the webs 82 and 92 are
folded along the score lines 94 and 104 so as to be disposed
internally of the tubular member which forms the container. Through
the utilization of these internally disposed webs as shown at 82
and 92 (it will be understood that similar webs are disposed
between each of the adjacent triangular panels) will provide
additional structural integrity to the container when it is
completed. The structural integrity is provided by the sealing of
each of the sections (halves) forming the triangular panel or web
together after they are folded against each other internally of the
cylinder. Obviously such positioning and sealing of each of webs 82
through 92 is accomplished as described with respect to webs 82 and
92 above.
[0038] The bottom closure is formed in a manner similar to that
above described with respect to the top closure. One major
difference, however, is that the webs 82' through 92' when formed
by folding the triangular-shaped panels 44-54 inwardly are disposed
externally of the cylindrical-shaped member as shown in FIG. 2.
[0039] The side portions forming each of these webs are then sealed
together against each other to provide the primary bottom support
and bottom seal for the container. The seal continues in such a way
that the sides of each of the panels are sealed together. Since the
triangular-shaped panels 44' through 54' are folded inwardly, their
apexes 56' through 66' will substantially join each other at the
longitudinal axis 122 of the cylindrical container. By so doing,
the protrusions 70' through 80' (FIG. 1) adjacent each of the
apexes will join each other. These protrusions are then also sealed
together preferably by ultrasonic welding to provide a fillet which
will seal over the pinhole which would otherwise exist in the
bottom closure of the container. Each of the webs which are
extending outwardly from the surface of the tubular member are then
pushed over to lie flat against its adjacent triangular-shaped
panel and is then sealed to that triangular-shaped panel preferably
by ultrasonic welding. Having each of the webs pushed over and
sealed in this manner forms a concentric offset pattern of webs
exposed on the outside of the bottom closure that are laying flat
against the triangular-shaped panels. The bottom closure structure
is then pushed inwardly into the interior of the tubular member to
form a substantially concave shape to the bottom closure structure.
This construction is shown in FIG. 4 to which reference is hereby
made. This provides a non-obstructive, concave-shaped bottom
closure and also provides additional structural integrity to the
bottom closure of the container. As is illustrated therein, the
additional triangular-shaped panels or webs 82' through 92' are
illustrated as each having been pushed or folded over to lie
against the adjacent triangular-shaped panels 46' through 54'
respectively and with the web 92' lying against the
triangular-shaped panel 44'. As can be clearly seen in FIG. 4, the
structure forming the completed closure includes a convex like top
closure 124 and a concave like bottom closure 126.
[0040] A structure wherein the top closure and bottom closures are
convex and concave, respectively, permit the stacking of the
containers one on top of the other for storage, shipping, shelf
space and the like. Such is shown in FIG. 5, to which reference is
hereby made. As is illustrated therein, a first container 128 is
stacked upon a second container 130 with the bottom concave closure
of the container 128 fitting over the top convex closure of the
container 130.
[0041] Also as shown in FIG. 6 to which reference is hereby made,
the hexagonal shape of the container constructed in accordance with
the principles of the present invention permit stacking of the
containers on a transporting device such as a pallet or truck 132
in such a way that there is an increased density of packing, that
is, there is no lost space with regard to adjacent containers. This
is one of the additional features of a container constructed in
accordance with the principles of the present invention. As will
become readily apparent to those skilled in the art the combination
of the stacking with the adjacent sides along the body of the
container as shown in FIG. 6 may be coupled with the nesting of the
bottom of one container on the top of an adjacent container as
shown in FIG. 5 to increase the number of containers or packages
which may be accommodated in any specific given area.
[0042] In some applications where strength of the packaging
container is of concern, it may be required to provide a laminate
structure wherein the central core of the lamination is of a
stronger structural material such as a corrugated material, a chip
board or the like. Such a structure is illustrated in FIGS. 7 and
8, to which reference is hereby made. As is therein shown, a
central core 132 is sandwiched between a first layer 134 of
preferably film material such as plastic and a second layer of a
similar material 136. Such material would be provided in a
continuous sheet form and would provide the base material from
which the blank as shown in FIG. 1 would be constructed. The blank
would then be provided with the score lines as above described to
provide the completed container. One principle difference, however,
would be that the protrusions on the sheet of material adjacent
each of the apexes of the triangular-shaped panels would be formed
only on the laminate as shown at 136 and as illustrated at 138-148
in FIG. 8. Otherwise, the structure and configuration of the blank
and of the container formed therefrom would be the same as
discussed above with respect to the blank of FIG. 1. The
protrusions 138-148 would, as is the case with protrusions as shown
in FIG. 1, be brought together when the top and bottom closures are
formed and then sealed to form a fillet to close what would
otherwise be a pinhole opening in the top and bottom closure.
[0043] It should be understood by those skilled in the art that
although the structures as discussed herein thus far have been
referred to as being airtight and/or liquid-tight sealed, such is
not always required depending upon the particular application. As
an example, some dry goods which do not deteriorate as a result of
exposure to air may be housed within a container constructed in
accordance with the principles of the present invention which does
not include the sealed fillet at the top and/or the bottom. It is
also contemplated that a container constructed in accordance with
the principles of the present invention may be utilized to hold a
bladder which is constructed of a food-grade material and will be
sealed to contain liquid. The bladder would be inserted into the
container constructed in accordance with the principles of the
present invention with the container designed to transport the
bladder and to support the bladder while the contents contained
therein are dispensed.
[0044] In some instances, it may be desirable to provide a
container constructed in accordance with the principles of the
present invention with a spout so that the user may dispense the
contents of the container as desired. By reference now to FIG. 9-A
through 9-D, there is shown a blank and the top portion of a
container constructed therefrom which includes such a spout. As is
sown in FIG. 9-A, the blank is substantially the same as that
illustrated in FIG. 1 with the exception that the triangular-shaped
panel 150 is designated as the panel defining the pouring spout.
Formed as an extension of the additional triangular-shaped panel or
web on each side of the triangular-shaped panel 150 is a tab 152
formed on the web 154 and a tab 156 formed on the web 158. The
construction of the container would be exactly the same as
described above with respect to FIG. 1, with the exception that the
two webs, 154 and 158, are formed to extend outwardly from the
container top closure as opposed to being disposed inwardly as was
the case with regard to the cylindrical member formed from the
blank shown in FIG. 1. In addition thereto, the triangular-shaped
panel 150 is not sealed shut as was the case with regard to the
triangular-shaped panels of the FIG. 1-type structure. When the top
closure is formed these additional triangular-shaped panels or webs
154 and 158 are folded over the triangular-shaped panel 150 as
shown in FIG. 9-B. Prior to folding the webs 154 and 158, as is
illustrated in FIG. 9-B, the two tabs 152 and 156 are first folded
over the front portion of the webs 154 and 158 and are left free.
Once folded in place, the two webs 154 and 158 are sealed by a spot
seal to hold the webs over the spout together. When the user
desires to open the spout for dispensing the contents contained
internally thereof, the user will first pry open the two webs 158
and 154, causing them to extend upwardly as is shown in FIG. 9-C.
The user then grasps the ends of the tabs 156 and 152 and pulls on
them to break the sealed webs apart. When such is done, the spout
can be opened as shown in FIG. 9-D for dispensing the contents
housed within the container. If the contents of the container are
not fully used, the spout can be refolded and closed by simply
pushing the spout back into the position as shown in FIG. 9-B and
refolding the webs 154 and 158 thereover and subsequently by
pushing on the very top of the top closure, the user can push the
entire top closure internally of the container so that it assumes a
concave shape similar to the bottom closure. The spout obviously
will not be sealed when this occurs because the seal was broken
when the tabs were pulled. However, it will stay closed and will be
positioned internally of the container below the perimeter so that
it will be in a position not to obstruct other items.
[0045] In some instances, it may be desired to provide a container
which is capable of housing a large amount of product such, for
example, as a five liter container of wine. Such a container can be
constructed utilizing the principles of the present invention and a
blank for constructing such a container is shown in FIG. 10. It
will be recognized by those skilled in the art that the blank as
shown in FIG. 10 is identical to the blank illustrated in FIG. 1
with the exception that on each side edge there is provided an
extension 160 and 162. The extensions 160 and 162 define an opening
164 and 166, respectively, while at the upper edge there is
provided an additional extension 168 and at the bottom edge an
additional extension 170. The extension 168 defines an opening 172
while the extension 170 defines an opening 174. It will be
understood by those skilled in the art that when the container is
formed by bringing the two side edges together as above described
with regard to the blank illustrated in FIG. 1, the extensions 160,
162, 168 and 170 will be folded along their respective score lines
176 and 178 so that the extensions protrude outwardly from the
container.
[0046] These extensions are sealed together, for example by the
utilization of ultrasonic welding or other sealing methods to
provide a handle or finger grip which may then be used by the user
to move or transport the filled container. Otherwise, the
construction of the top and bottom closures is identical to that
previously described.
[0047] In some instances, it may be desirable to ship a completed
container empty to be filled by the organization having the product
to be contained therein. Such a container is shown in FIG. 11, and
has been constructed by the equipment at the erection station.
However, this container, when pressed down, will collapse into a
flat position as shown at 200 and thus would occupy a minimum
amount of space for shipment. As is also illustrated, the container
200 has a separate spout closure 202 which, for example, would be a
molded plastic screw-on cap fitted over a spout which would be
separately affixed to the container 200.
[0048] It has been determined that under certain circumstances, as
opposed to manufacturing a container in accordance with the
principles of the present invention from a blank as shown in FIG. 2
and above described, that the structure may be formed as a tubular
member by extrusion and such is illustrated in FIG. 12 to which
reference is hereby made. The extruded tubular member 204, it will
be recognized by those skilled in the art, is substantially similar
to the structure as illustrated in FIG. 2, which illustrates the
blank of FIG. 1 formed into a tubular configuration. It will,
however, be noted that there are no flaps on the structure shown in
FIG. 13 since the structure has been extruded through an extrusion
die. However, the triangular-shaped panels and interspersed webs
therebetween are formed at each end of the member 204 in exactly
the same manner as was illustrated with regard to the blank of FIG.
1. Thus, once the score lines are placed as illustrated in FIG. 12
at each of the two ends of the extruded member 204 the top and
bottom closures can be formed in precisely the same manner as above
described.
[0049] By reference now to FIG. 14, there is illustrated in a
partial plan view a blank from which a container as shown in FIG.
13 can be constructed which may be utilized to contain food
products packed in a liquid such as tuna fish or the like. The
purpose of the container as shown in FIG. 13 is to provide a manner
in which the liquid can be drained from the container without first
dispensing the solid material housed within the package. As is
illustrated, the container has the webs such as shown at 206 and
208 folded over the triangular-shaped panel 210 very similar to
that described above with regard to the pouring spout structure. A
pair of tabs 212 are disposed on the webs and can be grasped to
open them to expose a plurality of perforations or openings 214.
Once such occurs, the container as shown in FIG. 13 may be held
over a drain or similar structure and turned upside-down to allow
the liquid within which the solid material is packed to drain
through the perforations 214. Thereafter, the container can be
opened and the internal contents dispensed. FIG. 14 illustrates in
partial plan view a blank 216 from which the container shown in
FIG. 14 is constructed. This blank is essentially the same as that
previously described with the exception of the perforations 214
formed in the triangular-shaped panel 210 thereof and the provision
of the tabs 212 on the side of the webs 218 and 220. As above
described when the triangular-shaped panels are folded inwardly to
form the top closure, the webs 218 and 220 would be caused to fold
outwardly and when sealed would be folded over to close the
openings 214 in the triangular-shaped panel 210 with the tabs 212
exposed for use in opening the container to drain the liquid
contained therein.
[0050] By referring now more particularly to FIG. 15, there is
illustrated a container 180 formed in accordance with the
principles of the present invention but which has an outward
configuration approaching that of a bottle such as, for example, a
wine bottle having a bottom portion for containing a substantial
amount of the wine contained therein and a necked down upper
portion. This bottle is generally in the shape of a white wine
bottle. The container 180 will be formed from a blank similar to
that illustrated in FIG. 1 but with the top closure being formed
from a plurality of triangular-shaped panels, only three of which
are illustrated at 182, 184 and 186. It will be noted that these
triangular-shaped panels are in the form of an isosceles triangle
having substantially longer sides than the base, whereas, in the
blanks previously illustrated, particularly as shown in FIG. 1, the
triangular-shaped panels as well as the webs interspersed there
between are more in the nature of an equilateral triangle. In
addition, the webs as shown at 188-198 are formed so that they
extend outwardly from the exterior surface of the container 180. It
should be understood that the webs may, if desired, be formed to
extend inwardly. These webs are formed precisely as above described
in that when the triangular-shaped panels are folded inwardly the
webs are caused to fold outwardly and are then sealed together
along their surfaces including the side edges of the
triangular-shaped panels to provide an appropriate seal. In
addition, the protrusions as above described would also be provided
and would be sealed to form a fillet closing the pinhole at the
upper end. When the user desires to dispense the contents of the
container 186 the user can grasp the webs appearing on opposite
sides of the web which the user desires to have as the pouring
spout and pull outwardly. For example, the user may grasp the webs
188 and 192 and pull outwardly away from the container thus
breaking the seal on the web 190 causing it to assume the shape of
a spout through which the wine or other liquid or dry goods,
contained within the container 180 may be dispensed. Although the
container 180 is illustrated as being sealed by, for example, the
ultrasonic sealing as above described along the webs, it should be
understood that an additional external closure can be utilized
which may be fabricated by injection molding or the like which
would fit over the top edge of the webs 188-198 with the webs being
left open as opposed to sealing them shut throughout their entire
lengths. This would then also provide the ability for the user to
remove the cap and dispense the contents through any one of the
openings thus remaining.
[0051] By referring now more particularly to FIGS. 16 and 17, there
is illustrated a container constructed in accordance with the
principles of the present invention which has the overall shape of
a red wine bottle, as is illustrated perspectively in FIG. 16. The
blank from which the bottle shown in FIG. 16 is constructed is
shown in plan view in FIG. 17, to which reference is hereby made.
As is shown in FIG. 17, the blank is a sheet 222 of material such
as PET which has been provided with score lines similar to those
described in conjunction with FIG. 1 above. The score lines are
provided so that the sheet 222 may be appropriately bent into a
tubular form and a bottom closure provided in accordance with the
principles as described in conjunction with FIG. 1 and the top of
the container may be provided with appropriate score lines to
accomplish the overall configuration of the top as illustrated in
FIG. 16.
[0052] As is shown in FIG. 17, the sheet 222 of material is
provided with score lines so that flat panels 224 through 234 are
formed along the sides, such as accomplished by the score lines 246
through 248. In addition, the score lines 246 and 248 provide the
additional flaps 252 and 252 which, when the sheet 222 is formed
into a tubular container, will come together and be sealed along
the sides to provide the appropriate liquid-tight, airtight seal on
the sides of the container. A transverse score line 254 is
provided, displaced from the bottom of the sheet 222, and defines
the base of the triangular-shaped panels 256 through 266 which form
the bottom closure of the container. Interspersed between the
triangular-shaped panels are the additional triangular-shaped
panels or webs 268 through 278. As was the case with respect to the
structure of FIG. 1 when the triangular-shaped panels 256 through
266 are pushed inwardly into the interior of the tubular member to
form the bottom closure, the webs 268 through 278 are interspersed
between adjacent panels and may extend inwardly into the container
or, if desired, outwardly from the container depending upon the
particular structure desired. In either case, the sides of the webs
are secured together as by ultrasonic welding or other sealing
means to provide the desired support structure. Adjacent each of
the apexes of the triangular-shaped members 256 through 266 there
is provided a protrusion 280 through 290 which when the
triangular-shaped members are pushed inwardly, their apexes will
join substantially at the longitudinal axis of the resulting
cylindrical or tubular structure and the protrusions 280 through
290 may then be welded together to form a fillet to seal a pinhole
which would otherwise result. It will be understood by those
skilled in the art that what has been described is the formation of
a bottom closure for the bottle as shown in FIG. 16 which is
substantially the same as the structure described above with
respect to the bottom closure for the container constructed from
the blank shown in FIG. 1.
[0053] To form the top closure from the blank as shown in FIG. 17,
two additional transverse score lines 292 and 294 are provided. A
plurality of additional score lines 296 through 318 are provided
between the transverse score line 292 and the upper edge 320 of the
sheet of material 222. As is seen, these additional score lines
intersect the score line 294 running transversely of the sheet of
material 222. The score lines extending between the score line 292
and the edge 320 of the sheet are constructed in such a manner as
to provide a plurality of triangular-shaped panels 322 through 332,
but constructed in such a manner that the upper portion of the
triangle is truncated by the score line 294 thus eliminating the
apex of each of the triangular-shaped panels. For example, the
score lines 296 and 298 provide opposite sides of a
triangular-shaped panel 322 with the score line 292 providing the
base thereof. The score line 294 truncates the upper portion of the
triangular-shaped panel 322. However, the score lines 296 and 298
extend upwardly to the upper edge 320 of the sheet of material 222
and as will be noted herein below provide an effective extension of
the panel 224 but of a smaller width. Another way to view the
structure is that the smaller width extension, for example as shown
at 336, would in fact be a continuation of the truncated portion of
the triangular panel 322, that is, the triangular panel 322 would
have an extension extending upwardly from the sides thereof as
illustrated at 336. Additional extensions 338 through 346 are also
illustrated extending upwardly from each of the triangular panels
324 through 332, respectively.
[0054] Interspersed between each of the panels 322 through 332 and
their extensions 336 through 346, respectively is a web as shown at
348 through 358. The panels and webs function in a manner similar
to that described with regard to the construction of the container
from the blank as shown in FIG. 1, with the exception that there
are no apexes of the panels but rather a continued extension
thereof. In construction, the panels 322 through 332 are folded
inwardly into the interior of the tubular member. As such is done,
the webs 348 through 358 are formed in such a manner that they
extend outwardly from the interior of the container. When such is
done, the side edges of the panels as defined by the score lines
296 through 318 are permitted to be disposed immediately adjacent
each other so that adjacent side edges of each of the panels are in
contact and the inside edges or surfaces of the webs are sealed
together to provide a structure somewhat like that shown in FIG.
16. However, the exteriorly extending webs are then folded over
against the outside surface of the panels and are then sealed to
provide the final appearance as shown in FIG. 16. For example as
shown in FIG. 16, the web 348 is folded to the right and lies
against the panel 324 and its extension 338. The web 350 is folded
over and lies against the panel 326 and its extension 340, and the
web 352 is folded over against the panel 328 and its extension
342.
[0055] It will be noted that when the bottle as shown in FIG. 16 is
constructed in this manner the upper end 360 remains open. As a
result, an appropriate closure structure is created to close and
seal the opening 360 at the top of the bottle structure as shown in
FIG. 16. Various types of closures can be constructed; such a
closure may be a molded plastic structure conforming to the
contours of the opening 360 or, alternatively, may be in the form
of a cork or similar structure more commonly associated with a wine
bottle.
[0056] Referring now more particularly to FIG. 18, there is
illustrated a container constructed in accordance with the
principles of the present invention which is similar to the
container shown in FIG. 15 but with the webs formed internally
thereof without a seal closing the top. In FIG. 18 however, a cap
362 is formed to mate with the upper open end of the container 364
and adapted to be sealed thereto along a line such as 366. The
upper end of the cap 362 is constructed to have a spout 368 which
is closed by a screw-on cap 370 as is conventionally recognized in
the industry. In a situation of this type, the upper closure 362
could be molded as an integral unit from plastic sealed along the
line 366 to the bottle 364 and then provided with a screw-on cap
370.
[0057] As shown in FIG. 19, a bottle 372 similar to that shown in
FIG. 18 is illustrated with the closure member 374, however, being
constructed in such a manner that it includes a spout which is
closed by a cork 376. The cork 376 may be the conventional type of
cork, for example, used in a wine bottle or the like.
[0058] By reference now to FIGS. 20 through 22, there is
illustrated in perspective view a container 378, 380 and 382,
respectively which is constructed so that it appears similar to the
container shown in FIG. 3 and is made from a blank as shown in FIG.
1 or an extruded blank as above described. In FIG. 20, a closure
member 384 is shown which includes, for example, a screw-on cap. In
FIG. 21, the structure is a spout-like member 386 which is formed
separately and adhered to or staked onto the outer surface of the
container 380. A flap 388 is utilized to close the spout 390 and to
be snapped open for dispensing the contents of the container 380
and to be returned if the contents are not all used up. In FIG. 22,
the container 382 is shown to include the well recognized
dispensing spout/closure 392 wherein the upper portion slides up or
down as shown by the arrow 394. When placed in the upward position,
the opening 396 is connected with the contents of the container 382
which may then be dispensed therefrom. The closure 392 when moved
downwardly disconnects the opening from the contents and closes the
same. The container 382 may simply be turned upside down to
dispense the contents or if additional force or volume is required,
it may be squeezed as is well known. There has thus been disclosed
a container which can be formed from a blank or from extruded
material and may have various forms and configurations depending
upon the particular application and contents to be contained
therein. The container may be formed automatically utilizing
typical well-known erection machinery. The blanks from which the
containers are formed may be shipped flat to a destination wherein
the erection machinery is available for use in forming the
container and typically will be in association with additional
automatic machinery to fill the container with the desired
contents. Many additional configurations and applications will be
recognized by those skilled in the art which will generate
containers of different shapes support structures and bladders than
those shown but still utilizing the principles of the present
invention to provide the desired top and bottom closures having
airtight and liquid-tight seals readily and easily formed.
* * * * *