U.S. patent application number 12/534494 was filed with the patent office on 2009-12-24 for container closure with segmented fusion ring.
This patent application is currently assigned to Arrow Innovations, LLC. Invention is credited to Robert W. Fox, Richard A. Gross, Dieter F. Lay.
Application Number | 20090314777 12/534494 |
Document ID | / |
Family ID | 40910074 |
Filed Date | 2009-12-24 |
United States Patent
Application |
20090314777 |
Kind Code |
A1 |
Gross; Richard A. ; et
al. |
December 24, 2009 |
Container Closure With Segmented Fusion Ring
Abstract
A container provides sealed storage for contents. The container
includes a composite top member formed of a panel and a frame. The
panel includes an opening for providing access to the contents of
the package. The frame includes a closure member that is molded in
an open position, and which can be moved to a closed position for
closing the opening in the panel. The container is formed of a
container body in the form of a tubular member formed to a desired
shape. The container body is closed using the top member that
closes a top opening of the container body, and a bottom member
that closes a bottom opening of the container body.
Inventors: |
Gross; Richard A.;
(Oconomowoc, WI) ; Lay; Dieter F.; (Oconomowoc,
WI) ; Fox; Robert W.; (Williamsburg, VA) |
Correspondence
Address: |
BOYLE FREDRICKSON S.C.
840 North Plankinton Avenue
MILWAUKEE
WI
53203
US
|
Assignee: |
Arrow Innovations, LLC
|
Family ID: |
40910074 |
Appl. No.: |
12/534494 |
Filed: |
August 3, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10996012 |
Nov 23, 2004 |
7568590 |
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12534494 |
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Current U.S.
Class: |
220/254.1 ;
220/254.4 |
Current CPC
Class: |
B29K 2101/12 20130101;
B29K 2307/00 20130101; B65D 17/28 20180101; B29C 66/71 20130101;
B29C 66/71 20130101; B65D 17/506 20130101; B29C 65/362 20130101;
B29K 2305/00 20130101; B65D 17/12 20130101; B29C 65/3676 20130101;
B29L 2031/565 20130101; B29C 2045/1673 20130101; B65D 43/02
20130101; B29C 66/71 20130101; B65D 17/502 20130101; B29C 66/71
20130101; B29C 66/71 20130101; B65D 47/08 20130101; B29C 65/3684
20130101; B29C 66/72343 20130101; B29C 65/08 20130101; B29C 66/71
20130101; B29C 66/5432 20130101; B29C 49/00 20130101; B29C 65/3612
20130101; B29K 2105/16 20130101; B29C 66/71 20130101; B65D 11/02
20130101; B29C 66/71 20130101; B29C 45/1671 20130101; B29C 65/3644
20130101; B29C 66/71 20130101; B29C 66/71 20130101; B29K 2077/00
20130101; B29K 2067/00 20130101; B29K 2025/06 20130101; B29K
2055/02 20130101; B29K 2027/06 20130101; B29K 2069/00 20130101;
B29K 2023/12 20130101; B29K 2023/06 20130101; B29K 2033/08
20130101 |
Class at
Publication: |
220/254.1 ;
220/254.4 |
International
Class: |
B65D 51/18 20060101
B65D051/18 |
Claims
1. A storage container, comprising: a container body having one or
more sides, an upper edge defining an upper opening, and a bottom;
and a top member secured to the upper edge and configured to
enclose the upper opening, wherein the top member includes an
interior panel having a panel opening; a removable seal member
secured to the interior panel so as to enclose the panel opening;
and a movable closure member carried by the top member, wherein the
movable closure member is interconnected with the top member so as
to provide movement of the closure member between an open position
for exposing the panel opening when the removable seal member is
removed, and a closed position in which the movable closure member
overlies and closes the panel opening.
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Description
BACKGROUND OF THE INVENTION
[0001] The present invention is generally related to providing
protection for various products such as foods, drugs, chemicals and
other products, including dry, semi-moist and liquid products as
well as products which contain particulate of varying sizes and
shapes.
[0002] The methods used to package and protect foods, drugs and
chemicals today include cans, bottles, jars, laminated canisters,
and pouches as well as semi-rigid plastic containers. Additionally,
most food, beverage and pharmaceutical products require more
product protection that can be achieved by a single polymeric
material. It is known that different combinations of materials can
be used together to achieve desired protection in the areas of gas,
moisture, chemical and thermal resistance properties, as well as
physical properties that cannot be achieved economically by other
means. In some instances, the desired properties can be achieved by
a physical blend of various materials, such as Dupont
Sclair.TM.films which are an alloy or blend of nylon and
polyethylene used in the packaging of fluid milk and other food
products. Recently, inorganic nano sized particles have been found
to make significant improvements in the gas barrier properties of
most polymers in which they are dispensed (see, e.g., JP
89308879.9). By themselves, these alloys have been useful in
providing some additional shelf life for refrigerated products or
for products that are fairly tolerant of oxygen.
[0003] In some instances, nano particles have been used in
conjunction with oxygen scavengers to improve the gas barrier of
the carrier polymer and provide a source of moisture for an
anti-oxidant of the oxygen scavenger that make up the alloy (see,
e.g., JP 63281964). These blends, which contain both an oxygen
scavenger and inorganic platelets to create a tortuous path, are an
improvement but do not, by themselves, provide the cost nor
esthetics and continuing protection required for extended shelf
life or shelf image of most oxygen intolerant, shelf stable foods
and other products.
[0004] For critical packaging requirements of this type, the
solution had been to package products in metal cans or glass jars.
This solution endured until the development of semi-rigid,
multi-layer, high-barrier plastics, which were commercialized in
the mid 1980's in packaging for such products as puddings, fruit
compotes and single serve entrees. Previously, multi-layer,
adhesive laminated, high-barrier thermoformed sheet technology had
been used for small containers to package jams and jellies for
single-serve, ready to use packs. These packs were produced based
upon aqueous coating technology utilizing Poly-Vinylidene Chloride
(PVDC). The PVDC coating, while very effective in a flat film form,
is not capable of being stretched more that 10% without breaking
apart. This prevents aqueous PVDC coatings from being used for
larger sized or deeper packages. To overcome extensibility
problems, further development resulted in an extrudable version and
a method of combining it in a laminar method through a process
known as coextrusion, as disclosed in U.S. Pat. No. 3,557,265.
[0005] Coextrusion was used in the creation of packages for both
high and low acid foods, with the first publicized application of
"plastic cans" being thermally processed (retorted) in the
mid-1970's. "Plastic cans" are prevalent today, and are typically
produced using a process known as solid-phase pressure-forming and,
more recently, using multi-layered injection blow molding and/or
extrusion blow molding processes. This process was developed in the
early 1970's in an effort to create sales opportunities for a newly
commercialized plastic polymer known as polypropylene. Johnson U.S.
Pat. No. 3,546,746 teaches that plastic articles can be
thermoformed not only from flat sheets but also from pre-cut shapes
called billets or blanks. U.S. Pat. No. 3,502,310 to Coffman
demonstrates an improved process involving heating the billets
continuously and forming several articles simultaneously.
[0006] The primary advantage of forming articles and specifically
containers from pre-formed plastic billets did not become obvious
until the mid 1980's when multi-layered plastic sheeting began to
be used for the packaging and preserving of processed shelf stable
foods. Plastic barrier containers have now become common and the
primary methods of producing containers for shelf-stable
applications are described below.
[0007] In a representative process, adhesively laminated or
coextruded sheet is web or sheet fed through a radiant or contact
heating oven and then thermoformed into its final shape by means of
vacuum and/or pressure, with an additional assist from a movable
plug to help distribute material for deep or tall containers, where
required. Containers are then trimmed out of the web or sheet by
trim tooling, which can either be a trim in place style which
removes the part from the web as part of the forming process, or an
off-line style in which parts can be trimmed out of the web or
sheet in a secondary trimming process. Web scrap generated in this
process typically exceeds 40% of the total web used in the process,
and is not uncommon to see scrap losses of 50% on round container
shapes. This high percentage of scrap increases the cost of the
finished parts, since not all of the scrap can be recovered. In
addition, the recoverable portion of the scrap is valued only at
the cost of the lowest priced material in the web, since the only
real value of such material is as a structural component. The
benefit of the more expensive barrier materials is lost when the
web skeleton is ground up to make regrind.
[0008] To maintain the barrier characteristics of the original
individual layers or phases of the laminated sheet, each individual
material must maintain its individual integrity. Grinding the web
skeleton into regrind destroys the integrity of the individual
layers. The resulting blended materials, when extruded into a
sheet, have none of the gas barrier characteristics of the original
multilayered sheet and in fact will have lost some of the physical
properties of the initial structural material used in the original
sheet manufacture. Additionally, some of the components in the
original multilayered sheet are typically approved for indirect
food contact only in high temperature food processing conditions.
Because these materials are no longer sandwiched into the center
portion of the sheet, it becomes necessary to place a separate food
contact layer between the regrind component and the food product to
insure that the materials, which are only acceptable for indirect
food contact, are kept in that position.
[0009] In addition, if the initial multilayered sheet was clear,
the use of regrind will diminish the clarity in direct proportion
to the amount of regrind being used in the sheet. For containers
which contain both polypropylene and EVOH (EVOH @ 1.5% or more), it
has been commercially demonstrated that structures which
incorporate web scrap of 15% or more are noticeably cloudy and at
levels of 20% become unacceptable for most applications. The web
skeleton that is not recovered and reused back into the manufacture
of sheet is then sold off as waste, with a salvage value less than
half that of the reused regrind, further increasing the cost of the
original parts produced from the web.
[0010] Reduced scrap thermoforming has been developed to a
commercial state in the U.S. by two patented methods, the first
being a scrapless forming process as shown in U.S. Pat. No.
3,947,204, and the second being a billet forming process as shown
in U.S. Pat. Nos. 3,502,310; 3,546,746; and 3,538,997. Both methods
incorporate process benefits described by Briston, et al., in
PLASTICS IN CONTACT WITH FOODS, 466 pages, received in the PTO
scientific library Dec. 31, 1974, as well as the process
improvements for transporting the billets identified in Frados et
al., PLASTICS ENGINEERING HANDBOOK, ISBN 0-442-22469-9, Library of
Congress Catalog Card Number 75-26508 pages 315 & 316,
describing the Hoffco/Beloit Forming System. The original forming
processes also benefited from the teachings of U.S. Pat. No.
3,538,997, which discloses the individual transportation of the
billets through the oven and into the forming station wherein the
carrier becomes a central part of the forming tool. Once formed,
the carrier tray transports the finished parts to the removal
station and begins the cycle again. This process is adapted in
Parkinson U.S. Pat. No. 4,836,764.
[0011] Plastic containers used in the packaging of shelf stable
foods required not only adequate barrier to prevent the oxidation
of the products contained within the package, but also had to
prevent the gain or loss of moisture as well. As discussed, it is
possible to design a multilayered package with the required barrier
properties. However, the closures for these types of packages
require a different approach or method so as to allow easy access
to the product. Initially, metallic foils laminated and/or
extrusion coated with polymeric thermal sealing compounds were
developed to provide controllable seal strengths for ease of
opening. In order to utilize these flexible-sealing membranes, a
sealing surface or flange had to be designed into the package.
These sealing surfaces typically were flat, although some
exceptions were found to be workable such as that created by Embro
and disclosed in U.S. Pat. No. 4,282,699.
[0012] Metal can ends have also been used to seal these newer
plastic containers with some success. However the can ends require
that the plastic container have a flange, which is approximately
0.021'' thick. However, the starting thickness of the sheet is
typically greater that 0.080'' and can be as thick as 0.115''. The
required thickness of the plastic container flanges thus
necessitates that the sheet be significantly reduced in thickness
in order to meet the specifications of the metal end. Reducing the
sheet thickness to this degree typically creates interlayer
adhesion and other problems. Interlayer adhesion of the compression
molded double seamable flange can cause operational problems if the
problems are not caught before they appear on the production floor.
Additionally, the cut edge exposes the hydroscopic barrier
materials to a high level of moisture pickup, thereby diminishing
its barrier properties.
[0013] It is an object of the present invention to provide a
product package that overcomes the above-noted problems with prior
art packages. It is a further object of the invention to provide a
multi-component product package that can be formed in various
shapes and sizes, and is not limited to use of round mating
surfaces as in the prior art. Another object of the invention is to
provide a product package providing a seal of high integrity
between the body and the end members of the package. A still
further object of the invention is to provide a product package
that can be efficiently manufactured with minimal waste using a
container body closed by a pair of end members. Another object of
the invention is to provide a product package that has the same
relative or improved amount of product protection as prior art
packages, while consuming much less energy in the comparative total
life cycle. A still further object of the invention is to provide a
product package in which the container body can be contoured
according to manufacturer or user requirements. Yet another object
of the invention is to provide a product package having a
reclosable opening to provide access to the contents of the
package, and which provides convenience in opening, dispensing and
re-closing the package. A further object of the invention is to
provide a product package that is capable of efficient and rapid
mass production, to provide a lower cost package than is currently
available for barrier property containers. A still further object
of the invention is to provide a product package that is relatively
inexpensive to manufacture, yet which provides improved barrier
characteristics and flexibility in package design over prior art
packages.
SUMMARY OF THE INVENTION
[0014] In accordance with the present invention, a product package
or storage container includes a container body having an interior
and including an upper edge defining an upper opening and a lower
edge defining a lower opening. The storage container further
includes a top member bonded to the upper edge to enclose the upper
opening, and a bottom member bonded to the lower edge to enclose
the lower opening. The top member includes a top member opening to
provide access to the interior of the container body. The top
member includes a panel, and the top member opening is in the form
of an opening in the panel. The top member further includes a frame
adapted for use in securing the top member to the upper edge
defined by the container body, and the frame includes a peripheral
outer area. The opening in the panel member is located inwardly of
the peripheral outer area of the frame. In a preferred embodiment,
the top member and the bottom member each include a fusion member
for use in bonding the top member and the bottom member to the
upper edge and the lower edge, respectively, of the container body.
Each fusion member is contained within a channel defined by one of
the top and bottom members. The channel defined by the top member
is configured to receive the upper edge of the container body, and
the channel defined by the bottom member is configured to receive
the lower edge of the container body. Each fusion member is formed
of a material that is responsive to externally applied energy, such
as radio frequency (RF) energy or an electromagnetic field.
Exposure of the fusion member to the externally applied energy,
such as RF energy or an electromagnetic field, results in
non-contact application of the fusion member to such energy that
heats the material of the fusion member to cause the fusion member
to bond with the edge of the container body. Each fusion member is
preferably injection molded into a peripheral edge portion, such as
a channel portion, of each end member. The fusion member may be
injection molded into the channel portion of the end member
simultaneously with insert molding the panel into the peripheral
edge portion of the end member.
[0015] The container body is preferably in the form of a tubular
member formed of deformable material. The tubular member may be
configured to define a contoured wall that is shaped in a forming
operation carried out prior to bonding the top member and the
bottom member to the container body. The forming operation includes
sealing the top and bottom openings of the tubular member, placing
the tubular member in a pliable state, and subjecting the interior
of the tubular member to internal pressure that applies an outward
force to the wall or by creating a vacuum between the exterior wall
of the tube and the surface of the mold, or a combination of both
forces acting upon the interior and exterior surfaces of the
pliable tube walls. The tubular member is contained within a mold
having contoured surfaces that contact the pliable wall of the
tubular member as the wall is moved outwardly, to form the
contoured wall when the interior of the tubular member is subjected
to internal pressure. The acts of sealing the top and bottom
openings of the tubular member are carried out by engaging top and
bottom seal members with the top and bottom edges of the container
body, respectively, and the act of subjecting the interior of the
tubular member to internal pressure may be carried out by applying
a pressurized gas to the interior of the tubular member through one
of the top and bottom seal members.
[0016] This aspect of the invention also contemplates a method of
making a container, substantially in accordance with the foregoing
summary.
[0017] In accordance with another aspect of the invention, a
storage container includes a container body having one or more
sides, an upper edge defining an upper opening, and a bottom; in
combination with a top member secured to the upper edge and
configured to enclose the upper opening. The top member includes an
interior panel having a panel opening, and a removable seal member
that encloses the panel opening. The top member further includes a
movable closure member that is interconnected with the top member
so as to provide movement of the closure member between an open
position for exposing the panel opening when the removable seal
member is removed, and a closed position in which the movable
closure member overlies and closes the panel opening. The top
member includes a frame to which the interior panel is bonded, and
the frame includes means for bonding the frame to the upper edge of
the container body. The means for bonding the frame to the upper
edge of the container body is preferably in the form of a fusion
ring, as described previously. In a preferred form, the interior
panel defines a peripheral edge area, and the interior panel is
insert molded during formation of the frame. The frame is
configured to surround the peripheral edge area of the interior
panel.
[0018] The movable closure member is formed along with the frame,
and is preferably interconnected with a platform area of the frame
that overlies the panel opening. In the open position, the movable
closure member overlies an area of the interior panel adjacent the
panel opening. Release means, in the form of a release agent, is
interposed between the interior panel and the movable closure
member for preventing the movable closure member from adhering to
the interior panel during formation of the movable closure member.
The movable closure member may include a tab member adapted for
manual engagement by a user to facilitate movement of the movable
closure member between the open and closed positions. The interior
panel includes a recess, and the tab member at least partially
overlies the recess to enable manual engagement of the tab member
from within the recess.
[0019] The movable closure member is interconnected with the top
member via a hinge connection that provides pivoting movement of
the movable closure member between the open and closed positions.
The hinge connection is in the form of a hinge area of material
located between the movable closure member and the panel opening
that is formed along with the frame and the movable closure member.
The platform area of the frame is formed to define a lip area that
surrounds the panel opening, and the hinge area of material is
located between the lip area and the closure member. In one form,
the hinge area of material is at least in part defined by an
underlying protrusion defined by the interior panel during
formation of the platform area and the movable closure member.
[0020] This aspect of the invention further contemplates a top
member for use in closing an upper opening defined by a container
and a method for manufacturing a reclosable top for a container,
substantially in accordance with the foregoing summary.
[0021] While the aspects of the present invention may be employed
separately to provide a container or package that has improved
characteristics or features compared to the prior art, it is
contemplated that the various aspects of the invention are
particularly advantageous in combination to deliver significant
advantages and benefits both to the manufacturer and to the
consumer, in an efficient and cost effective manner.
[0022] Various other features, objects and advantages of the
invention will be made apparent from the following description
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The drawings illustrate the best mode presently contemplated
of carrying out the invention.
[0024] In the drawings:
[0025] FIG. 1 is an isometric view of a container incorporating the
various aspects of the present invention;
[0026] FIG. 2 is an isometric topside view of a lid or top member
for the container of FIG. 1, showing the top member as molded and
showing a seal membrane in place over an opening that provides
access to the interior of the container, and further showing the
movable closure member in the open position;
[0027] FIG. 3 is an isometric underside view of the container top
member of FIG. 2;
[0028] FIG. 4 is a top plan view of the container top member of
FIG. 2;
[0029] FIG. 5 is a cross sectional view along line 5-5 of FIG.
4;
[0030] FIG. 6 is an isometric topside view of the container top
member of FIG. 2, showing the seal membrane removed and further
showing the movable closure member in the open position in which
the opening in the top member is exposed to provide access to the
interior of the container;
[0031] FIG. 7 is a top plan view of the container top member of
FIG. 2, showing the movable closure member in the closed position
in which the opening in the top member is closed to prevent access
to the interior of the container;
[0032] FIG. 8 is a cross sectional view along line 8-8 of FIG.
7;
[0033] FIG. 9 is an isometric topside view of the container top
member of FIG. 2, showing the movable closure member in the closed
position in which the opening in the top member is closed to
prevent access to the interior of the container;
[0034] FIG. 10 is an isometric view of a fusion ring incorporated
in the container top member of FIG. 2 and/or the bottom member of
FIG. 13 for use in bonding the top member to the upper edge of a
container body or for use in bonding the bottom member to the
bottom edge of a container body;
[0035] FIG. 11 is an isometric view of the fusion ring of FIG. 10
in combination with a plastic panel incorporated in the top member,
showing the fusion ring and the panel prior to the molding of the
frame of the top member;
[0036] FIG. 12 is an isometric view of another embodiment of a
fusion ring adapted to be incorporated in the container top member
of FIG. 2 and/or bottom member of FIG. 13;
[0037] FIG. 13 is an isometric topside view of a bottom member for
use in forming the container of FIG. 1;
[0038] FIG. 14 is a cross sectional view along line 14-14 of FIG.
15;
[0039] FIG. 15 is a bottom plan view of the container bottom member
of FIG. 13;
[0040] FIG. 16 is an isometric view of a container body, in the
form of an extruded tube, for use in making the container of FIG.
1;
[0041] FIG. 17 is an isometric view of the container body of FIG.
16, showing the container body captured between upper and lower
seal members for use in forming the container body;
[0042] FIG. 18 is an isometric view of the container body of FIG.
16 captured between the upper and lower seal members and positioned
between a pair of mold sections for use in forming the container
body;
[0043] FIG. 19 is a top plan view of the container forming mold
sections of FIG. 18 closed upon the seal members and the container
body prior to forming the container body;
[0044] FIG. 20 is a cross sectional view along line 20-20 of FIG.
19;
[0045] FIG. 21 is a cross sectional view similar to FIG. 20,
showing the container body after forming within the mold
sections;
[0046] FIG. 22 is an isometric view similar to FIG. 18, showing the
container body after forming within the mold sections;
[0047] FIG. 23 is an isometric topside view showing the formed
container body;
[0048] FIG. 24 is an isometric underside view of the container body
of FIG. 23 showing a bottom member secured to a bottom edge defined
by the container body;
[0049] FIG. 25 is an elevation view of the assembled container as
in FIG. 1, showing the container top member secured to the top of
the container body and the bottom member secured to the bottom of
the container body;
[0050] FIG. 26 is a cross sectional view along line 26-26 of FIG.
25;
[0051] FIG. 27 is an enlarged segmented view within circle 27 of
FIG. 26;
[0052] FIG. 28 is an enlarged segmented view within circle 28 of
FIG. 26;
[0053] FIG. 29 is an isometric topside view of a blow molded or
thermoformed container body for use in forming a container in
accordance with the present invention;
[0054] FIG. 30 is an isometric topside view of the container body
of FIG. 29 showing the top member of FIGS. 2-9 secured to the upper
edge of the container body;
[0055] FIG. 31 is front elevation view of the container and top
member of FIG. 30;
[0056] FIG. 32 is an isometric topside view showing an extruded
tube container body and a bottom member secured to the bottom edge
of the container body;
[0057] FIG. 33 is a bottom plan view of the bottom member secured
to the bottom edge of the container body of FIG. 32;
[0058] FIG. 34 is a cross sectional view along line 34-34 of FIG.
33;
[0059] FIG. 35 is an enlarged segmented view within circle 35 of
FIG. 34;
[0060] FIG. 36 is an isometric view of the extruded tube container
body and bottom member of FIG. 32, captured between a lower holder
and an upper seal member for use in forming the container body;
[0061] FIG. 37 is an isometric view of the extruded tube container
body and bottom member of FIG. 32, captured between the lower
holder and the upper seal member and positioned between a pair of
mold sections for use in forming the container body;
[0062] FIG. 38 is a top plan view of the upper seal member of FIGS.
36 and 37 and the container forming mold sections closed upon the
container body;
[0063] FIG. 39 is a cross sectional view along line 39-39 of FIG.
38, showing the container body prior to forming within the mold
sections;
[0064] FIG. 40 is a cross sectional view similar to FIG. 39,
showing the container body after being formed within the mold
sections;
[0065] FIG. 41 is an isometric view of the formed container body of
FIG. 40 captured between the lower holder and the upper seal
member;
[0066] FIG. 42 is an isometric view of the formed container body of
FIGS. 40 and 41 after removal from between the mold sections;
[0067] FIG. 43 is an isometric view similar to FIG. 16,
illustrating a double wall container body for use in making a
container in accordance with the present invention;
[0068] FIG. 44 is a top plan view of the container body of FIG.
43;
[0069] FIG. 45 is an isometric view of the container body of FIG.
43, showing the ends of the container body crimped together in
preparation for assembly into the container in accordance with the
present invention;
[0070] FIG. 46 is a top plan view of the container body of FIG.
45;
[0071] FIG. 47 is a section view taken along line 47-47 or FIG.
46;
[0072] FIG. 48 is a section view similar to FIG. FIG. 26, showing
the container body of FIGS. 43-47 incorporated into a container in
accordance with the present invention;
[0073] FIG. 50 is a top plan view of tooling for producing formed
container bodies, for use in forming a container as shown in FIG.
1, in an alternative molding process known as continuous vacuum
forming; and
[0074] FIG. 50 is a section view taken along line 50-50 of FIG.
49.
DETAILED DESCRIPTION OF THE INVENTION
[0075] The following is a detailed description of the preferred
embodiment of the invention. It is important to note that the
invention is not limited to the shapes, sizes and proportions shown
in the figures and discussed in the following description. Even
though the embodiments shown and discussed are in the form of round
or cylindrical packages and package components, it is anticipated
that other shapes such as square, rectangular, oval, triangular,
and polygonal, etc. could be used. Likewise, it is anticipated that
other features of the design, such as the lid opening and mating
closure, could also have a multitude of shapes, sizes and
proportions. The preformed containers shown are not restrictive to
the specific embodiment with which they are associated in the
figures.
[0076] This invention seeks to replace the more energy and/or
material intensive packages with packages which provide the same
relative amount of product protection while consuming much less
energy in their comparative total life cycle. Additionally, the
package seeks to provide improvements or benefits not possible with
current forms of packaging. These improvements relate both to the
manufacturing processes as well as more use-oriented benefits.
While it may be possible to obtain packages which contain one or
more of these improvements or benefits, our system is the first to
offer all of these benefits to the manufacturer and/or consumer at
one time, in a cost effective manner.
[0077] To be considered as possible replacements for traditional
metal, double seamed ends, it is necessary for plastic closures to
provide the same product protection, food process compatibility and
ease of container access offered by traditional closures. Today,
using the molding technologies disclosed herein, it is possible to
produce all-plastic closures that meet the minimum criteria
established by the traditional closures.
[0078] The features of a container lid or bottom cap that includes
a frame made from a thermoplastic polymeric material, a pre-formed,
pre-treated, and pre-die-cut, multi-layered, semi-rigid,
high-barrier plastic panel and a fusion ring made from an
electro-magnetic, radio frequency, or ultrasonic polymeric, fusible
material suitable for bi-injection molding, and the process for the
manufacture of the container lid and bottom cap, are disclosed in
copending patent application serial number PCT/US03/25713 filed
Aug. 18, 2003 and entitled MULTI-COMPONENT PACKAGING SYSTEMS FOR
SHELF STABLE FOODS AND BEVERAGES, the disclosure of which is hereby
incorporated by reference.
[0079] The capability to mold multiple materials (in addition to
insert molding and in-mold heat-sealing) allows for plastic ends to
be developed which can be designed to provide adequate keeping
properties in terms of gas and moisture barriers. Additionally, the
ends can be designed to thermally weld to the contacted surfaces of
the container by the use of ultra-sonic, electro-magnetic or RF
heating of the fusion bonding system. Heating of the bonding system
by either of these means will raise the temperature of the fusion
bonding material and the materials it contacts to their fusion
temperature. Once this temperature is achieved, the similar
materials contained in both the container and the closure exchange
molecules at the interface of these adjacent articles to be joined
and a thermal/fusion weld is made. The preferred process of
induction is not new but previously had required the insertion of
electromagnetically and/or RF excitable or conductive materials
such as wire, metal foil or a metal-powder filled gasket or liquid
adhesive between the parts to be welded (U.S. Pat. Nos. 5,114,507;
6,258,312; 3,620,875; 3,620,876; 4,201,306, all hereby incorporated
by reference).
[0080] The electromagnetic and/or conductive materials, or RF
responsive materials, that may used in our fusion ring may include
powders of stainless steel, tin oxide, iron, carbon black,
carbonaceous or other materials. The preferred material will
include iron powder similar to those described in expired U.S. Pat.
Nos. 3,620,876 and 3,620,875 except that any and all materials will
be required to be acceptable for direct food contact by the U.S.
Food and Drug Administration when the fusion ring is to be used in
a package containing human or non-human food. The preferred
materials that meet these criteria include both a sponge iron
powder (FG 100) as manufactured by the Hoeganaes Company, Inc of
Ramsey, N.J. or a carbonyl iron powder (Ferronyl) as produced by
ISP Technologies Inc. of Freehold, N.J. or other similar food grade
iron powders.
[0081] Containers may be made of polymeric materials typically used
for packaging and include materials such as polyethylene,
polystyrene, polypropylene, polyester, polycarbonate,
acrylonitrile-butydene-styrene, acrylic-terpolymers, nylon or
polyvinyl-chloride as well as other materials used in the
manufacture of packages.
[0082] Referring to FIG. 1, a container 100 in accordance with the
present invention generally includes a container body 102 that
defines an interior and open top and bottom ends, in combination
with a lid or top member 104 secured to the upper end of container
body 102, and a bottom cap or member 106 secured to the lower end
of container body 102. Container 100 is adapted to contain solid or
liquid products in any flowable form, such as foods, drugs,
chemicals and other products, including dry, semi-moist and liquid
products.
[0083] Referring to FIGS. 2-9, top member 104 includes a frame 110,
an interior panel 112, and a closure member 114. Frame 110 defines
an outer periphery that surrounds an outer edge defined by panel
112. Frame 110 further includes a platform 116 that overlies a
portion of panel 112 and is located inwardly of the outer periphery
defined by frame 110. Platform 116 includes an opening 118 (FIG.
3). Top member 104 further includes a removable seal member 120
that is secured to platform 116 over opening 118. Seal member 120
is configured to be secured to the upper surface of platform 116
outwardly of opening 118, to provide an air-tight seal of opening
118.
[0084] Panel 112 of top member 104 is formed of a suitable
pre-treated, multi-layered, semi-flexible, high-barrier
thermoplastic material, as is known in the art. Panel 112 is
selected to have the desired gas, moisture barrier and physical
properties required by the product or commercial sterilization
process of container 100. Panel 112 may be formed by die cutting
from a sheet in a shape to match the shape of frame 110, and is
formed to include a panel opening 122 defined by a peripheral edge.
Panel 112 is further formed to define an outer raised flange 124,
and an angled ring section 126 located inwardly of outer flange
124. Panel 112 further includes a generally linear transverse
protrusion 128 located adjacent platform opening 118. Platform 112
further includes a recess 130 defined by a sloped bottom wall 132
and an end wall 134. Recess 130 is located on panel 112 so as to be
opposite platform opening 118 relative to protrusion 128.
[0085] Frame 110 of top member 104 includes a shoulder 138 that
overlies flange 124 of panel 112. A peripheral outer rim 140
extends upwardly from shoulder 138. Below shoulder 138, frame 110
defines a channel 142 formed by an outer leg 144 and an inner leg
146. A fusion member, in the form of a fusion ring 148, is located
within channel 142. Fusion ring 148 is configured so as to be
located within the upper extent of channel 142 between outer leg
144 and inner leg 146. Fusion ring 148 defines an upper surface
that underlies panel flange 124 and is formed so as to have a
similar outside diameter as the outside diameter of panel 112. The
properties and function of fusion ring 148 are set forth in the
above-referenced copending application serial number
PCT/US03/25713.
[0086] Platform 116 and closure member 114 are formed integrally
with frame 110. Platform 116 generally defines an upper wall 150
that overlies the upper surface of a portion of panel 112 about
panel opening 122. Platform 116 defines an inner edge 152. Platform
116 occupies the area between inner edge 152 and shoulder 138, so
as to overlie the portion of panel 112 in which panel opening 122
is formed. Platform 116 further includes a depending peripheral lip
154 that surrounds and encapsulates the edge of panel 112 that
defines panel opening 122, and the inner edge of platform lip 154
defines platform opening 118. Platform lip 154 is configured so as
to surround the area of panel 112 adjacent panel opening 122, with
a portion of lip 154 being located below panel 112 and a portion of
lip 154 being located inwardly of the edge of panel 112 defining
panel opening 122. In the event panel 112 includes an EVOH layer,
lip 154 prevents the EVOH layer from being exposed to high
temperature products, which is restricted under current FDA
regulations.
[0087] Closure member 114 of top member 104 is formed in an open
position, as shown in FIGS. 1-6. Closure member 114 includes a
generally planar closure wall 158, in combination with a peripheral
closure rim 160 having a shape that matches that of platform
opening 118. Closure wall 158 is joined to platform upper wall 150
via a hinge section 162 that overlies panel protrusion 128. Hinge
section 162 provides movement of closure member 114 between an open
position and a closed position, in a manner to be explained. In
addition, closure member 114 includes a tab 164 that is located
over panel recess 130 when closure member 114 is in the open
position. A flexible hinge 166 is interposed between tab 164 and
closure wall 158 of closure member 114.
[0088] FIG. 10 illustrates fusion ring 148. In the illustrated
embodiment, fusion ring 148 is circular in shape. It is understood,
however, that fusion ring 148 may have any other desired shape
according to the configuration of the container into which fusion
ring 148 is incorporated. Fusion ring 148 includes opposed pairs of
passages 170, in the form of depressions or recesses that extend
below the upper edge of fusion ring 148 and throughout the width of
fusion ring 148. FIG. 12 illustrates an alternative fusion ring
148' formed of separate ring sections 172a, 172b, 172c and 172d,
which are separated by spaces or gaps 174 to provide passages
between the inner and outer surfaces of fusion ring 148'.
[0089] FIG. 11 shows panel 112 and fusion ring 148 prior to molding
of panel 112 and fusion ring 148 into top member 104. Flange 124 of
panel 112 is positioned so as to rest on the upper surface of
fusion ring 148. Passages 170 communicate between the inner and
outer surfaces of fusion ring 148, and panel flange 124 overlies
passages 170.
[0090] Representatively, the process for the manufacture of top
member 104 is as follows. A first mold section and a second mold
section are configured to form a cavity for molding of fusion ring
148. After fusion ring 148 is formed, the second mold section is
removed and panel 112 is placed onto fusion ring 148, as shown in
FIG. 11, such that flange 124 of panel 112 contacts and rests on
the upper surface of fusion ring 148. A third mold section is then
positioned over the first mold section, so as to enclose fusion
ring 148 and panel 112. The first and third mold sections have
cavities that correspond in shape to frame 110 including platform
116 and closure member 114. Thermoplastic polymeric material in a
flowable state is then injected into the mold cavities so as to
form the various contours, features and surfaces of frame 110,
platform 116 and closure member 114 as shown and described.
Passages 170 in fusion ring 148 enable the thermoplastic material
to flow through fusion ring 148, to form the areas of frame 110
that underlie panel 112. In the event fusion ring 148' is used, the
spaces or gaps 174 between the section 172a-172d allow material to
form the areas of frame 110 that underlie panel 112. Top member 104
is then removed or ejected from the mold sections in any
satisfactory manner. Seal member 120 may be applied to platform 116
to enclose platform opening 118 either before or after top member
104 is released or ejected from the mold.
[0091] When seal member 120 is removed, so as to expose platform
opening 118, closure member 114 may be employed to selectively
close platform opening 118. FIGS. 7-9 show the closed position of
closure member 114, in which closure member 114 closes platform
opening 118. To move closure member 114 from the open position to
the closed position, the user grasps tab 164 of closure member 114
and applies an upward force to closure member 114. Recess 130 in
panel 112 facilitates such manual engagement of tab 164 by the
user. Application of the upward force to closure member 114
functions to pivot closure member 114 about hinge section 162. The
user continues such pivoting movement of closure member 114 away
from the open position, so that closure member rim 160 is moved
toward platform opening 118 by application of a downward force to
closure member 114. The user continues such pivoting movement of
closure member 114 until closure member rim 160 is engaged within
platform opening 118. Tab 164 pivots about hinge 166, so as to
allow tab 164 to extend upwardly when closure member 114 is in the
closed position. In this manner, tab 164 can be subsequently used
to facilitate movement of closure member 114 from the closed
position back toward the open position, when it is once again
desired to expose platform opening 118. It is also contemplated
that tab 164 may be formed without hinge 166, so that the angular
position of tab 164 on closure member 114 remains fixed. In this
embodiment, rim 140 of top member 104 is preferably provided with a
recess or gap within which tab 164 is received when closure member
104 is pivoted to the open position.
[0092] During manufacture, a release agent is coated or printed
onto the upper surface of panel 112 that underlies closure member
114. In this manner, when closure member 114 is made by injecting
the flowable thermoplastic material onto and about panel 112, the
material that forms closure member 114 does not adhere to or
otherwise bond with the underlying material of panel 112, to enable
closure member 114 to easily be moved from its open position toward
its closed position.
[0093] FIGS. 13-15 illustrate bottom member 106 of container 100,
which is generally similar in construction to top member 104.
Bottom member 106 includes a frame 178 having a shoulder 180 and an
upwardly extending rim 182 (which extends downwardly when bottom
member 106 is secured to container 100). Frame 178 further includes
a channel 184 defined by shoulder 180 in combination with an outer
leg 186 and an inner leg 188. A fusion ring 200 is contained within
the upper extent of channel 184.
[0094] Bottom member 106 further includes an interior panel 202
located inwardly of frame 178. Panel 202 defines an outer
peripheral edge that is surrounded by frame 178. Panel 202 may be
formed with undulations 204, which, in combination with the
material choice and thickness, are configured to encourage any
package deformation caused by an increase or decrease in the
internal pressure of the package to occur in panel 202.
[0095] Panel 202 is constructed similarly to panel 112, e.g. by die
cutting a multi-layered, semi-rigid, high-barrier plastic panel to
the desired shape. Bottom member 106 is also constructed similarly
to top member 104, by first molding fusion ring 200 in first and
second mold sections having a cavity shaped so as to correspond to
the final desired shape of fusion ring 200. Fusion ring 200 is
constructed similarly to fusion ring 148, including passages, gaps
or spaces that establish communication between the inner and outer
surfaces of the fusion ring. After fusion ring 200 is formed, the
second mold section is removed and lower panel 204 is placed on
fusion ring 200 so that the outer edge of lower panel 204 rests on
the upper surface of fusion ring 200. A third mold section, in
conjunction with the first mold section, fusion ring 200 and panel
202 then forms a cavity for frame 178. Flowable thermoplastic
material is then injected into the cavity to form frame 178, and
the passages in fusion ring 200 below panel 202 enable the
thermoplastic material to flow through fusion ring 200 below lower
panel 204, to provide complete molding of the areas of frame 178
located inwardly of fusion ring 200 and below lower panel 204.
Bottom member 106 is then released, ejected or otherwise removed
from the mold.
[0096] FIG. 16 illustrates container body 102 prior to container
body 102 being formed to a contoured shape as shown in FIG. 1.
Container body 102 is preferably in the form of an extruded plastic
member having a desired length according to the final configuration
of container 100. Container body 102 is in the form of a tubular
member defining an interior that is accessible through a top
opening 210 and a bottom opening 212. Container body 102 may be
formed of any satisfactory material, and may be formed of one or
more layers, depending upon the requirements of container 100.
[0097] FIGS. 17-23 illustrate the manner in which container body
102 is formed to the final desired shape. To form container body
102, an upper holder or seal member 214 is engaged with the upper
end of container body 102 so as to overlie and enclose upper
opening 210, and a lower holder or seal member 216 is engaged with
the lower end of container body 102 so as to overlie and enclose
bottom opening 212. One of seal members 214 and 216, such as seal
member 214, includes a pressurizing passage 218.
[0098] Container body 102 is then converted to a deformable state,
such as by exposure to a radiant heat source, to soften the
material of container body 102 to a pliable state. The heated
container body 102 is then positioned between a pair of mold
sections 220a, 220b, which have contoured inner mold surfaces 222a,
222b, respectively, that cooperate to define an internal cavity
having a shape that corresponds to the final desired shape of
container body 102 when mold sections 220a, 220b are moved
together. Mold sections 220a, 220b are then closed onto upper seal
member 214, lower seal member 216 and container body 102, as shown
in FIGS. 19 and 20. Mold sections 220a, 220b representatively have
rims or shoulders 224a, 224b, which are received within recesses
defined by seal members 214, 216 and which engage the upper and
lower edges of container body 102. With this construction, top and
bottom openings 210, 212, respectively, of container body 102 are
maintained in the original shape and sealed.
[0099] A source of pressurized fluid, such as pressurized gas, is
then brought into communication with seal member passage 218, as
shown in FIG. 20. Representatively, the source of pressurized gas
may be an air blow tube 226. Pressurized air is then applied
through blow tube 226 and passage 218 to the interior of container
body 102. Such introduction of pressurized air causes the pliable
material of the walls of container body 102 to deform outwardly and
into contact with the mold surfaces 222a, 222b of mold sections
220a, 220b, respectively, thus forming the desired shape of
container body 102. The formed container body 102 is then cooled
within the mold sections 220 and/or by air after mold sections
220a, 220b are opened. The cooled and formed container body 102 is
then removed from upper and lower seal members 214, 216,
respectively, to provide container body 102 having a shape as shown
in FIG. 23.
[0100] It is understood that the specific shape of container body
102 as shown in the drawings is representative, and that any other
shape of container body 102 may be provided as desired.
[0101] Alternatively, it is contemplated that the pliable material
of the walls of container body 102 may be deformed outwardly into
contact with the mold surfaces 222a, 222b of mold sections 220a,
220b, respectively, using a vacuum forming process. In this case,
negative air pressure is introduced in the space between the walls
of container body 102 and mold surfaces 222a, 222b, such as through
vacuum ports formed in mold sections 220a, 220b that open onto mold
surfaces 222a, 222b. Such introduction of negative air pressure
causes the walls of container body 102 to deform outwardly into
contact with mold surfaces 222a, 222b, to form container body 102
to the desired shape. Non-pressurized air is drawn through tube 226
and passage 218 into the interior of container body 102, to add to
the volume of air required as the interior volume of container body
102 expands during the vacuum forming operation. The air introduced
into the interior of container body 102 may also be pressurized, in
order to assist in the vacuum forming of container body 102.
[0102] FIG. 24 shows bottom member 106 secured to the lower end of
container body 102, in a manner to be explained. FIG. 25 shows both
top member 104 and bottom member 106 secured to the upper and lower
ends, respectively, of container body 102, to form container
100.
[0103] FIG. 27 illustrates the manner in which the upper end of
container body 102, shown at 230, is secured to top member 104.
Similarly, FIG. 28 shows the manner in which the lower end of
container body 102, shown at 232, is engaged with bottom member
106.
[0104] In order to produce container 100, bottom member 106 is
first secured to lower end 232 of container body 102. To accomplish
this, container body lower end 232 is positioned within upwardly
facing channel 184 defined by frame 178 of bottom member 106, so
that the lower edge of lower end 232 rests on fusion ring 200.
Outer leg 186 and inner leg 188 of channel 184 guide lower end 232
into contact with the exposed surface of fusion ring 200. Fusion
ring 200 is then exposed to an electromagnetic or radio frequency
field while a downward force is applied to container body 102. As
disclosed in copending application Serial No. PCT/US/25713 filed
Aug. 18, 2003, such exposure of fusion ring 200 to the
electromagnetic and/or RF field functions to permanently and
hermetically fuse bottom member 106 to lower end 232 of container
body 102, due to the heating of fusion ring 200 to a semi-molten
state by the non-contact, electromagnetic and/or RF excitement of
the metallic and/or carbonaceous fillers contained within fusion
ring 200, to embed the lower portion of container body lower end
232 into the semi-molten fusion ring 200. After bottom member 106
is applied and cooled, container body 102 can be filled with
product in a manner as is known in the art.
[0105] After container body 102 is filled, top member 104 is
applied to upper end 230 of container body 102. This is
accomplished by first dropping top member 104 onto upper end 230 of
container body 102 so that upper end 230 is received within channel
142. Legs 144 and 146 of channel 142 function to guide top member
104 onto upper end 230 of container body 102, until the upper edge
of upper end 230 contacts the downwardly facing surface of fusion
ring 148. As before, fusion ring 148 is then exposed to an
electromagnetic and/or RF field while a downward force is applied
to top member 104. Such exposure of fusion ring 148 to the
electromagnetic and/or RF field functions to heat fusion ring 148
to a semi-molten state by the non-contact electromagnetic and/or RF
excitement of the metallic and/or carbonaceous fillers contained
within fusion ring 148, to embed the upper portion of container
body upper end 230 into the semi-molten fusion ring 148. Top member
104 is thus permanently and hermetically fused to the top rim of
container body 102. After filling and application of top member
104, the contents of container 100 can be accessed by removing seal
member 120. In a preferred form, seal member 120 includes a pull
tab portion that extends past platform edge 152, which facilitates
manual engagement with seal member 120. As noted previously,
container 100 can be conveniently reclosed by moving closure member
114 from the open position to the closed position.
[0106] Rim 140 of top member frame 110, in combination with channel
142, provide controlled stacking of top members 104, one on top of
the other, for improved handling of top members 104 prior to
application to the top of container body 102. In addition, rim 182
of bottom member frame 178 is configured to nest with rim 140 of
top member frame 110, to provide controlled stacking of containers
100 on top of one another. Shoulder 138 of top member frame 110
provides a seating surface for rim 182 of bottom member frame 178.
Further, rims 182 and 140 are configured to control lateral
movement between stacked containers.
[0107] Inner leg 146 of channel 142 and inner leg 188 of channel
184 are of sufficient length to contain any melted residue from
respective fusion rings 148, 200, in order to minimize contact
between the product and the electromagnetic or RF responsive
polymeric, fusible material of the fusion rings. The outer legs
144, 186 of channels 142, 184, respectively, may be shorter, longer
or of equal length relative to the inner legs, depending upon the
aesthetic and any additional functional requirements such as to
facilitate application to the container body. For example, in the
event the outer leg is longer than the inner leg, the top or bottom
member can be presented to the container at an angle. As the top or
bottom member is lowered, the outer leg catches onto the rim of the
moving container, to extract the member from a feeder trough and to
guide the member into place on top of the container rim.
[0108] FIGS. 29-31 illustrate an alternative container body, shown
at 236, which is adapted to be closed using top member 104 in
accordance with the present invention. In this embodiment,
container body 236 may be blow molded, thermoformed, or formed in
any other satisfactory manner, so that container body 236 has an
integral bottom wall. With this construction, bottom member 106 is
not employed, and the open upper end of container body 236 is
closed using top member 104 in the same manner as described above.
This construction provides a reclosable top member for a container
body of this type.
[0109] FIGS. 32-42 illustrate an alternative construction that is
contemplated as being within the scope of the present invention,
and like characters will be used where possible to facilitate
clarity.
[0110] In this construction, a bottom member 106a is applied to the
lower end of a container body 102a before container body 102a is
formed to the final desired shape. In this embodiment, bottom
member 106a defines an outer leg 186a of substantially greater
height than inner leg 188a. The bottom end of container body 102a
is fused to fusion ring 200a as described above.
[0111] After bottom member 106a is applied to the bottom end of
container body 102a, upper holder or seal member 214a is engaged
with the upper end of container body 102a and bottom member 106a is
received within a cavity or recess defined by a lower holder 236,
as shown in FIG. 36. Referring to FIG. 37, mold sections 238a, 238b
are moved into engagement with upper seal member 214a and lower
holder 236. Mold sections 238a, 238b define inner mold surfaces
240a, 240b that cooperate to define a cavity corresponding in shape
to the final desired shape of container body 102a. Container body
102a is then heated so that its walls are in a pliable state, and
pressurized air is then applied to the interior of container body
102a. The walls of container body 102a are then forced outwardly,
as shown in FIG. 40, to conform to the mold surfaces 240a, 240b
defined by mold sections 238a, 238b, respectively. In this
embodiment, outer leg 186a of channel 184a has a contour that forms
a part of the surface against which the walls of container body
102a are forced, so as to partially define the shape of container
body 102a. Container body 102a is then cooled, and mold sections
238a, 238b are removed as shown in FIG. 41. Upper seal member 214
and lower holder 236 are then removed, to provide the formed
container body 102a and bottom member 106a as shown in FIG. 42.
Container body 102a can then be filled with product and a top
member applied as before so as to enclose and seal the container
body.
[0112] FIGS. 43-48 illustrate an alternative container body, shown
at 248, which is adapted to be used in forming a container 100 in
accordance with the present invention. In this embodiment,
container body 248 has a double wall construction, including an
inner wall 250 and an outer wall 252. A series of ribs 254 extend
between and interconnect inner wall 250 and outer wall 252. Ribs
254 cooperate with inner wall 250 and outer wall 252 to define a
series of air chambers 256, which extend throughout the length of
container body 248. Representatively, container body 248 may be
formed in an extrusion process in which inner wall 250, outer wall
252 and ribs 254 are formed simultaneously, although it is
understood that container body 248 may be formed in any other
satisfactory process. Either or both of inner wall 250 and outer
wall 252 may have a multi-layer construction including a barrier
properties layer, if desired. Container body 248 is cut to a
desired length after the extrusion process, according to the
desired final configuration of the container 100.
[0113] After being formed as described above, container body 248 is
prepared for assembly into container 100 by crimping or otherwise
sealing the ends of container body 248 as shown in FIGS. 45-47, to
seal air chambers 256. To accomplish this, container body 248 is
held between an upper holder and a lower holder, each of which has
a plug or other member that fits into the interior of container
body 248 at its upper and lower ends, respectively. Each plug
conforms to the shape of the interior of container body 248 at its
associated end of container body 248. Exterior crimping devices are
then engaged with the ends of container body 248, and close upon
outer wall 252 to move outer wall 252 toward inner wall 250 at the
ends of container body 248. The crimping process also involves
heating of the ends of container body 248, so that the material of
outer wall 252 and inner wall 250 merges together to form an upper
rim 258 and a lower rim 260. The formation of upper rim 258 and
lower rim 260 in this manner is such that rims 258, 260 enclose the
upper and lower ends, respectively, of air chambers 256. After the
ends of container body 248 are crimped together and sealed as
described above, container body 248 is utilized in the same manner
as container body 102 described above, to produce a container 262
(FIG. 48) that has a similar overall construction to container 100.
That is, a lid or top member 104 is applied to upper rim 258 and a
bottom cap or member 106 is applied to lower rim 260, in the same
manner as described above with respect to the application of top
and bottom members 104, 106, respectively, to the upper and lower
ends, respectively, of container body 102 With this construction,
container 262 has the same advantages over the prior art as
described above with respect to container 100, and also includes an
insulating feature provided by the presence of sealed air chambers
256 within container body 248.
[0114] In an alternative forming method, known as continuous vacuum
forming, a polymeric tube is continuously extruded and travels
between sets of mold halves. A system of this type is schematically
illustrated at 300 in FIGS. 49 and 50. In this forming method,
moving tooling in the form of a continuous or sequential series of
mold halves 302 are mounted to spaced apart runs of a means of
conveyance, such as continuous belts trained about pulleys or
sprockets, in a manner as is known. An extruded tube is positioned
and advanced between the mold halves 302, which are moved together
onto the pliable polymeric material of the extruded tube. An
internal sizing mandrel or sleeve 304 is carried within the
interior of the continuously extruded polymeric tube. The sizing
mandrel or sleeve 304 is connected to the end of the die and
provides a low pressure seal, to allow the use of internal positive
pressure in addition to external negative pressure to facilitate
the forming of the container walls. Once the container walls are
formed and cooled, the containers 102 are separated (cut) from each
other. A system such as this is shown and described in Held, Jr.
U.S. Pat. No. 3,837,517 and in Kemerer et al U.S. Pat. No.
5,167,781, the disclosures of which are hereby incorporated by
reference.
[0115] Crimping can also be accomplished in the continuous vacuum
forming system 300 by having the moving tooling press the pliable
polymeric material of the tube against the internal sizing mandrel
or sleeve 304 that is carried within the interior of the
continuously extruded polymeric tube.
[0116] While the invention has been shown and described with
respect to specific embodiments, it is understood that various
alternatives and modifications are possible and are contemplated as
being within the scope of the present invention. For example, and
without limitation, the container top member, body and bottom
member may be a variety of shapes, including non-circular shapes,
in addition to the circular shapes as shown in the drawing figures.
Likewise, the top member of the container may have a variety of
shapes for the platform opening and the rim of the closure member,
in addition to the specific shape as shown and described. Further,
while mating rims have been shown for providing a container
stacking feature, it is contemplated that any other satisfactory
mating stacking feature could be designed into the container bottom
member which would eliminate the need for the rim feature on the
container top member, in which the case the frame of the top member
can be flat. Likewise, appropriate stacking features can be
designed into the container top member, which can therefore
eliminate the need for the rim feature on the container bottom
member, so as to enable the bottom of the frame to be flat. While
the fusion ring has been shown as being formed either in segments
or with channels, it is contemplated that any other satisfactory
conduit-type arrangement may be incorporated into the fusion ring
so as to allow for the flow through of thermoplastic material
during injection molding of the frame about the fusion ring. In
addition, the top member can be applied to a container formed by a
method other than the container body and bottom cap type as
described. Other container types can also be thermoformed or blow
molded with a continuous bottom and a flangeless rim at the top.
Further, the container body may be simply the extruded tubular
member, without being deformed to the shape as shown and
described.
[0117] While the invention has been shown and described primarily
in connection with the use of electromagnetic or RF energy to heat
the fusion member to bond the top and/or bottom member to the
container body, it is also contemplated that any other type of
energy may be employed in order to excite an internal fusion member
in a non-contact manner to bond the top and/or bottom member to the
container body.
[0118] It is also contemplated that the container may be
constructed so as to eliminate the reclosable feature provided by
closure member 114. In this construction, top member 104 is formed
with platform 116 so as to overlie a portion of panel 112 and to
enclose the edge of panel opening 122, and closure member 114 is
eliminated.
[0119] In addition, the container may be filled through the
platform opening after the container lid is secured to the
container. In this case, the high barrier peel-away seal member is
applied after filling. Further, it is also contemplated that the
container top member can be secured to the body first, with the
container then being filled with product and the bottom cap applied
thereafter, in a reverse series of steps to those shown and
described in FIGS. 33-42.
[0120] It is also contemplated that the container may be fitted
with an optional, removable snap-on overcap to serve a variety of
purposes. The outer wall of the overcap is designed to fit over the
outside leg of the container lid. A bead on the inside surface of
the outer wall of the overcap locates below the outside edge of the
outer leg of the container lid. The overcap also includes a rim to
act in the same manner as the rim of the frame. In a case such as
this, an overcap with a rim may be used to eliminate the need for a
rim on the frame of the container top member. The overcap acts as a
protective cover for the package or for the remaining contents of
the package after the package has been opened and the tear-away
seal member has been removed and discarded. Optional openings in
the overcap may serve as a means for venting heat and steam from
the package during microwaving or cooking of the contents of the
package.
[0121] Various alternatives and embodiments are contemplated as
being within the scope of the following claims particularly
pointing out and distinctly claiming the subject matter regarded as
the invention.
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