U.S. patent application number 10/812451 was filed with the patent office on 2005-10-06 for food product package having nested cup and cup holder.
This patent application is currently assigned to Sonoco Development, Inc.. Invention is credited to Morrow, J. Mark.
Application Number | 20050220939 10/812451 |
Document ID | / |
Family ID | 35054629 |
Filed Date | 2005-10-06 |
United States Patent
Application |
20050220939 |
Kind Code |
A1 |
Morrow, J. Mark |
October 6, 2005 |
Food product package having nested cup and cup holder
Abstract
A package for a food product that is packaged in dry form and is
prepared by adding liquid such as hot water, comprises a primary
container formed as a tapered plastic drinking cup, and a cup
holder also formed as a tapered plastic cup. The primary container
and cup holder are configured so they are nestable inside each
other. The package is convertible between a packaged configuration
in which the cup holder is nested inside the primary container, and
a serving configuration in which the primary container is nested
inside the cup holder. The food product can be contained in the
primary container or in the cup holder. A membrane can seal the cup
holder closed. An outer wrapper such as a shrink band or label can
hold the cup holder in the primary container and provide tamper
evidence, and can also serve as a moisture and/or oxygen
barrier.
Inventors: |
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.
|
Family ID: |
35054629 |
Appl. No.: |
10/812451 |
Filed: |
March 30, 2004 |
Current U.S.
Class: |
426/86 |
Current CPC
Class: |
B65D 81/3216 20130101;
B65D 51/185 20130101 |
Class at
Publication: |
426/086 |
International
Class: |
B65B 029/02 |
Claims
What is claimed is:
1. A package for containing a food product that is prepared for
consumption by mixing with liquid, the package serving as a vessel
for the preparation as well as a container in which the prepared
food product is served, the package comprising: a primary container
comprising a tapered plastic cup having a radially outwardly
projecting rim at a top end of the cup; and a cup holder comprising
a tapered plastic cup having a radially outwardly projecting flange
at a top end thereof and an elongated skirt depending from the
flange such that a channel is defined between the skirt and a side
wall of the cup holder; the cup holder and primary container being
complementarily configured to be nestable inside each other such
that the package is convertible between a packaged configuration in
which the cup holder is nested inside the primary container, and a
serving configuration in which the primary container is nested
inside the cup holder; the channel of the cup holder being
configured to receive the rim of the primary container when the
package is in the packaged configuration.
2. The package of claim 1, further comprising complementary locking
features on the cup holder and primary container for locking the
primary container into the cup holder in the serving configuration
of the package.
3. The package of claim 2, wherein the locking features comprise a
projection formed on one of the cup holder and primary container
and a recess formed on the other of the cup holder and primary
container, the projection engaging the recess in the serving
configuration.
4. The package of claim 3, wherein the recess is formed in an inner
surface of the cup holder and the projection is formed on an outer
surface of the primary container.
5. The package of claim 4, wherein the recess comprises a groove
extending circumferentially about the inner surface of the cup
holder, and the projection comprises a raised region extending
circumferentially about the primary container.
6. The package of claim 5, wherein the cup holder includes a second
recess, the recesses being axially spaced, and the primary
container includes a second raised region, the raised regions being
axially spaced.
7. The package of claim 1, further comprising spacing members
formed on one of the cup holder and primary container for spacing a
side wall of the cup holder from a side wall of the primary
container in the serving configuration of the package, whereby the
cup holder provides thermal isolation from the primary
container.
8. The package of claim 7, wherein the spacing members comprise
ribs.
9. The package of claim 8, wherein the ribs project inwardly from
an inner surface of the side wall of the cup holder and abut an
outer surface of the side wall of the primary container in the
serving configuration.
10. The package of claim 1, comprising a food product contained in
the package in the packaged configuration.
11. The package of claim 10, wherein the cup holder is shorter than
the primary container such that in the packaged configuration a
space is defined between a bottom wall of the cup holder and a
bottom wall of the primary container, the food product being
disposed in said space.
12. The package of claim 11, further comprising a wrapper wrapped
about at least the top ends of the cup holder and primary container
in the packaged configuration for sealing the food product in the
package and holding the cup holder and primary container
together.
13. The package of claim 12, wherein the wrapper comprises a shrink
film.
14. The package of claim 10, wherein the food product is contained
in the cup holder in the packaged configuration.
15. The package of claim 14, further comprising a membrane sealed
to the top end of the cup holder for sealing the food product in
the package.
16. The package of claim 15, further comprising a wrapper wrapped
about at least the top ends of the cup holder and primary container
in the packaged configuration for holding the cup holder and
primary container together.
17. The package of claim 16, wherein the wrapper comprises a shrink
film.
18. The package of claim 10, wherein the food product comprises a
dry beverage mix.
19. The package of claim 1, wherein the rim of the primary
container comprises a flat flange.
20. The package of claim 1, wherein the primary container and cup
holder comprise thermoplastic.
21. The package of claim 20, wherein the primary container and cup
holder are thermoformed.
22. The package of claim 1, wherein the skirt of the cup holder is
flared radially outwardly toward a lower end of the skirt.
23. The package of claim 1, wherein the lower end of the skirt
includes a radially outwardly projecting flange.
24. The package of claim 1, further comprising a shrink film
wrapped about the top ends of the cup holder and primary container
in the packaged configuration, the shrink film extending at least
partway along the length of the primary container, the shrink film
including a line of weakness allowing an upper portion of the
shrink film to be detached from a lower portion of the shrink film
and removed from the package while the lower portion of the shrink
film remains wrapped about the primary container such that the
package can be converted to the serving configuration.
25. The package of claim 24, wherein the shrink film is printed
with visual elements.
26. The package of claim 1, further comprising a food product
contained in the primary container in the packaged configuration,
and a shrink band wrapped about the top ends of the cup holder and
primary container to seal the package and hold the primary
container and cup holder together, the shrink band terminating at
an upper edge proximate the flange at the top end such that the cup
holder remains open at the top end, permitting multiple ones of the
packages to be nested inside one another in the packaged
configuration.
27. A package for containing a food product that is prepared for
consumption by mixing with liquid, the package serving as a vessel
for the preparation as well as a container in which the prepared
food product is served, the package comprising: a primary container
comprising a tapered plastic cup; and a cup holder comprising a
tapered plastic cup having a radially outwardly projecting flange
at a top end thereof; the cup holder and primary container being
complementarily configured to be nestable inside each other such
that the package is convertible between a packaged configuration in
which the cup holder is nested inside the primary container, and a
serving configuration in which the primary container is nested
inside the cup holder; and a flexible web attached to at least the
top end of the cup holder when the package is in the packaged
configuration; wherein the web and at least one of the cup holder
and primary container comprise materials providing a barrier
against the passage of moisture and/or oxygen.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a package for containing a dry food
product, such as instant coffee, powdered cocoa, dehydrated soup,
etc., wherein the package includes a cup in which the food product
is served after mixing the food product with water.
BACKGROUND OF THE INVENTION
[0002] Some convenience food products and hot beverages, such as
coffee, hot cocoa, or soup, are often prepared from dry starting
ingredients by adding hot water. For instance, one existing
commercial product comprises dry soup mix contained in an expanded
polystyrene (EPS) cup and sealed closed by a membrane. To prepare
and serve the soup, the membrane is removed and hot water is added
to the cup. The soup can be eaten out of the EPS cup. Expanded
polystyrene offers the advantage of being a good thermal insulator,
so that the cup can be held comfortably in the hand as the soup is
consumed.
[0003] Instant coffee and hot cocoa also are often prepared and
served in expanded polystyrene cups, although typically the dry
instant coffee or powdered cocoa mix are not packaged in the cup,
but rather are packaged separately in jars or single-serving
packets.
[0004] While EPS is a good thermal insulator, it has other
drawbacks. For instance, EPS by itself is a relatively poor oxygen
and water vapor barrier. Thus, for packaging food products that
must be protected from oxygen and/or water vapor infiltration, it
is generally necessary to use barrier EPS, which comprises a layer
of EPS laminated to a barrier film. Widespread recycling of
consumer food packages made of barrier EPS has not yet taken hold,
which means such packages wind up in landfills.
SUMMARY OF THE INVENTION
[0005] The present invention addresses the above needs and achieves
other advantages, by providing a package for a food product such as
instant coffee, powdered cocoa, dry soup mix, or the like, that is
prepared and served in the package, wherein the package can be
formed of materials that are widely recycled. In preferred
embodiments the package can be thermoformed from polypropylene or
the like.
[0006] In one embodiment of the invention, the package comprises a
primary container formed as a tapered plastic cup, and a cup holder
also formed as a tapered plastic cup. The cup holder nests inside
the primary container when the food product is initially placed in
the package and the package is sealed. The food product can be
contained in the bottom of the primary container, or alternatively
in the bottom of the cup holder. A membrane is sealed across the
top of the cup holder when it contains the food product. A shrink
film can envelope an upper portion, or all, of the package to hold
the primary container and cup holder together and also prevent
infiltration of debris, water vapor, and gases. The package is
convertible into a serving configuration by removing the shrink
film and removing the cup holder from the primary container. If the
food product is contained in the cup holder, the membrane is peeled
off and the food product is poured from the cup holder into the
primary container. Then the primary container is nested inside the
cup holder, and hot or cold water is added and mixed with the food
product. The cup holder provides thermal insulation so as to
protect the consumer's hand from directly contacting the primary
container when the package is held in the hand. Thus, hot beverages
or food can be consumed from the package while the package is held
comfortably in the hand.
[0007] The primary container includes a radially outwardly
projecting rim at the top. The cup holder has a radially outwardly
projecting flange at its top end, and a skirt depends from the
flange to form an annular channel between the skirt and the side
wall of the cup holder. In the packaged configuration of the
package, when the cup holder is nested into the primary container,
the rim of the primary container is received up into the channel of
the cup holder. A snap fit between the cup holder and primary
container can be provided, if desired. The skirt preferably is
flared outwardly toward its lower end, and includes an outwardly
projecting flange at its lower end, to form a relatively wide
structure that is easily gripped. The skirt and flange also help
provide stability to the package when inserted into an automobile
cup holder.
[0008] The shrink film that is wrapped about the package in the
packaged configuration can provide tamper evidence. In one
embodiment, the film extends at least part of the way down the
primary container and includes a line of weakness (perforations or
the like) permitting an upper part of the film to be detached from
a lower part so that the upper part can be removed to convert the
package into the serving configuration. The lower part of the film
remains on the primary container. The film can be printed with
visual elements such as indicia or graphics.
[0009] In a preferred embodiment of the invention, the cup holder
and primary container have cooperating locking features that engage
each other when the package is in the serving configuration to lock
the primary container into the cup holder. The locking features can
comprise one or more projections and recesses. For example, in a
preferred embodiment the inner surface of the cup holder defines a
circumferential groove and the outer surface of the primary
container defines a circumferential ridge or raised region that
engages the groove of the cup holder. There can be more than one
groove and ridge axially spaced apart. The groove(s) and/or
ridge(s) can extend completely or partially about the
circumference.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0010] 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:
[0011] FIG. 1 is a perspective view of a package in accordance with
a first embodiment of the invention, shown in the packaged
configuration prior to initial opening of the package;
[0012] FIG. 2 is a cross-sectional view of the package taken on
line 2-2 in FIG. 1;
[0013] FIG. 3 is a perspective view showing the package in the
serving configuration;
[0014] FIG. 4 is a cross-sectional view taken on line 4-4 in FIG.
3;
[0015] FIGS. 5A through 5D depict a series of steps for converting
the package from the packaged configuration to the serving
configuration;
[0016] FIG. 6 is a cross-sectional view of a package in accordance
with a second embodiment of the invention;
[0017] FIG. 7 shows a cup holder of the package in accordance with
yet another embodiment of the invention;
[0018] FIG. 8A is a perspective view of a package in accordance
with a still further embodiment of the invention; shown in the
packaged configuration;
[0019] FIG. 8B shows the primary container of the package of FIG.
8A after the cup holder has been removed;
[0020] FIG. 9 is a perspective view of a package in accordance with
still another embodiment of the invention;
[0021] FIG. 10 is a cross-sectional view along line 10-10 in FIG.
9; and
[0022] FIG. 11 shows a stack of nested packages as depicted in FIG.
9.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The present inventions 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,
these inventions 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.
[0024] A package 10 in accordance with a first embodiment of the
invention is shown in FIGS. 1 through 4. The package comprises a
primary container 20 formed as a tapered plastic cup, and a cup
holder 30 also formed as a tapered plastic cup. The primary
container 20 includes a bottom wall 22, a generally conical side
wall 24 that is integrally formed with and projects upward from the
bottom wall, and a rim 26 formed at the top end of the side wall.
The rim 26 projects radially outwardly from the side wall 24, and
can have various forms; in the illustrated embodiment the rim is a
flat flange, but alternatively the rim could be rolled or otherwise
configured. The primary container also includes a pair of raised
regions or ridges 28 that extend about the circumference of the
side wall 24 near the bottom wall 22 and project radially outwardly
from the side wall. As further described below, these ridges 28
cooperate with features on the cup holder 30.
[0025] The cup holder 30 includes a bottom wall 32 and a generally
conical side wall 34 that is integrally formed with and projects
upward from the bottom wall. At the top end of the side wall 34, a
flange 35 projects radially outwardly and is joined at its outer
edge to a skirt 36 that depends from the flange. The skirt flares
slightly outwardly toward its lower end. An outwardly projecting
flange 37 extends from the lower end of the skirt. Between the side
wall 34 of the cup holder and the skirt 36, an annular channel 38
is defined. A pair of circumferential grooves 39 are formed in the
inner surface of the cup holder 30 for cooperating with the ridges
28 of the primary container, as further described below.
[0026] The package 10 is convertible between a packaged
configuration as shown in FIGS. 1 and 2, and a serving
configuration as shown in FIGS. 3 and 4. The packaged configuration
is the configuration in which the package is filled and sealed by
the food packager, and in which the package is shipped to a retail
store and displayed. In the packaged configuration, the cup holder
30 is nested inside the primary container 20; the cup holder and
primary container are suitably configured to allow such nesting,
for example by virtue of the cone half-angle of their side walls
24, 34 being substantially the same, and their bottom walls 22, 32
having substantially the same outer diameter. The rim 26 of the
primary container is received up into the channel 38 of the cup
holder; a snap fit between the rim and the cup holder can be
provided, if desired, to resist inadvertent separation of the cup
holder and primary container.
[0027] In the embodiment of FIGS. 1-4, a food product 40 is
contained in the cup holder 30 in the packaged configuration of the
package. The food product can be of various types, including but
not limited to instant coffee power or crystals, powdered drink mix
of other types, dry soup mix, cocoa powder, etc., to which liquid
(e.g., hot or cold water, milk, etc.) is added to prepare the food
product for consumption. To seal the food product in the cup
holder, the package preferably includes a membrane 42 that is
attached by any suitable method (including heat-sealing, adhesively
attaching, etc.) to the flange 35 of the cup holder. The cup holder
30 can be formed to provide a barrier against the passage of
moisture and oxygen; for example, the cup holder can be formed of a
multi-layered material wherein at least one layer comprises a
barrier material. The membrane 42 likewise can serve as a gas
and/or moisture barrier, as well as preventing the food product
from escaping the cup holder and preventing foreign matter from
infiltrating the cup holder after the package is initially filled
and sealed. The membrane 42 can be a single-layer or multi-layer
structure including suitable polymer, foil, and/or paper layers as
required for the particular needs of the package.
[0028] The package 10 also includes an outer wrapper 44 that is
wrapped about the upper ends of the cup holder and primary
container. The wrapper 44 can serve to prevent the cup holder and
primary container from being detached from each other until the
consumer opens the package, as well as to provide an indication of
tampering. The wrapper 44 preferably is a shrink film that is
heat-shrunk about the package so that it tightly surrounds the
package in such a manner that removing it can be accomplished only
by breaking it, similar to shrink wraps or bands used on other
types of packaging.
[0029] As depicted in FIGS. 5A through 5D, when the consumer
desires to consume the food product, the wrapper 44 is removed and
the cup holder 30 is removed from the primary container 20 (FIG.
5B); the membrane 42 is peeled off the cup holder 30 and the food
product 40 is poured into the primary container (FIG. 5C); and the
primary container 20 is nested into the cup holder 30 and liquid is
added to the primary container and mixed with the food product.
[0030] FIG. 4 shows the package in the serving configuration. The
bottom wall 22 of the primary container 20 is in substantially
abutting relation with the bottom wall 32 of the cup holder. The
ridges 28 of the primary container 20 engage the grooves 39 in the
inner surface of the cup holder 30 in a snap-fit fashion so as to
"lock" the primary container in the cup holder, although the
snap-fit only resists rather than completely prevents detachment;
the primary container can be removed from the cup holder by pulling
upward on it with sufficient force to deform the ridges 28 and
grooves 39.
[0031] FIG. 6 depicts a package 10' in accordance with another
embodiment of the invention. The package includes a primary
container 20 and cup holder 30 substantially as previously
described. In this embodiment, however, the food product 40 is
contained in the primary container 20 in the packaged
configuration. The primary container can be formed to provide a
barrier against the passage of moisture and oxygen; for example,
the primary container can be formed of a multi-layered material
wherein at least one layer comprises a barrier material. The food
product is contained in a space between the bottom wall 22 of the
primary container and the bottom wall 32 of the cup holder; this
space is provided by virtue of the cup holder being shorter in
length that the primary container. The package also includes an
outer wrapper 44' that tightly surrounds the upper ends of the
primary container and cup holder to keep them from coming apart and
to provide tamper evidence, as in the previously described
embodiment. In this embodiment, the wrapper 44' can also serve the
function of sealing the food product 40 against infiltration of
moisture and/or oxygen, if such a barrier is required for the food
product. The wrapper can incorporate any suitable barrier material
for moisture and/or oxygen.
[0032] FIGS. 8A and 8B depict a package 10" in accordance with yet
another embodiment of the invention. The package includes a primary
container 20 and cup holder (not visible) substantially as
described in the previous embodiments, and a wrapper 44" that
tightly surrounds the upper ends of the primary container and cup
holder to hold them together. The wrapper can also provide a
barrier function, if needed, as well as tamper evidence. In this
embodiment, the wrapper includes a line of weakness 46, such as a
line of perforations, which permits an upper part 48 of the wrapper
above the line 46 to be severed from a lower part 50 of the wrapper
below the line and removed from the package. The lower part 50 of
the wrapper thus remains on the primary container 20. FIG. 8B shows
the primary container 20 after the cup holder has been removed from
it. The lower part 50 of the wrapper can include visual elements
52, such as indicia as shown, and/or graphic elements. The
positioning of the lower part 50 of the wrapper and the visual
elements 52 can be such that the visual elements remain visible
above the top of the cup holder when the primary container is
inserted into the cup holder.
[0033] FIG. 7 shows an alternative embodiment of a cup holder 30'
in accordance with the invention. The cup holder 30' is generally
the same as the cup holder previously described, except that the
side wall 34 includes ribs 54 that project radially inwardly from
the inner surface of the side wall. The ribs 54 are configured to
abut the outer surface of the primary container when the package is
in the serving configuration as in FIGS. 3 and 4. The ribs thus
ensure that there is an air space between the cup holder and the
primary container, thereby thermally isolating the cup holder from
the primary container. This is especially beneficial when the
primary container is used for hot beverages or foods that would
make the primary container too hot to be comfortably held in the
hand.
[0034] The outer wrapper or shrink band of the previously disclosed
embodiments extends fully across the top end of the package.
However, this would prevent nesting of multiple packages. In
another embodiment of a package 110 shown in FIGS. 9 through 11,
the packages are configured to be nestable in a stack. The package
110 includes a primary container 120 and cup holder 130
substantially as previously described. The food product 40 is
contained in the primary container 120. The two components are held
together and the package is sealed by an outer wrapper or shrink
band 144 that does not extend fully across the top end of the cup
holder. The inner or upper edge 146 of the band 144 extends
partially over the top of the cup and closely fits against the
inner surface at the top end of the cup holder. Accordingly, the
cup holder remains open at the top. Therefore, multiple packages
110 can be nested in a stack as shown in FIG. 11. In this
embodiment, the cup holder and primary container can both
incorporate a barrier material to resist passage of moisture and/or
oxygen, as can the shrink band.
[0035] In the various embodiments described above, the primary
container and cup holder advantageously are formed of a suitable
plastic material. Thermoplastic materials that are certified by
applicable regulatory agencies for food contact can be used, such
as polypropylene, polyethylene, polystyrene, and others. These
parts can be formed by various techniques. One advantageous
technique is thermoforming.
[0036] Many modifications and other embodiments of the inventions
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the inventions are
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.
* * * * *