U.S. patent application number 13/608987 was filed with the patent office on 2013-04-04 for multi-function condiment container.
This patent application is currently assigned to H.J. HEINZ COMPANY. The applicant listed for this patent is Craig S. CALDWELL, John MARSHALL, William F. RASILE. Invention is credited to Craig S. CALDWELL, John MARSHALL, William F. RASILE.
Application Number | 20130084367 13/608987 |
Document ID | / |
Family ID | 43011669 |
Filed Date | 2013-04-04 |
United States Patent
Application |
20130084367 |
Kind Code |
A1 |
CALDWELL; Craig S. ; et
al. |
April 4, 2013 |
MULTI-FUNCTION CONDIMENT CONTAINER
Abstract
A container for condiments includes a container portion having
generally planar bottom, a generally parallel flange, and defining
a cavity having a discharge spout adjacent the parallel flange. The
container further includes a generally planar cover portion
fashioned from a material more flexible that the material of the
container portion and secured to the flange by an adhesive. The
container preferably includes a weakened region transversely
aligned with the spout but not having fluid communication
therewith. Moreover, the container preferably includes a peel
initiating structure aligned with the spout but spaced therefrom
effective to reduce the peeling force required to separate the
cover portion from the container portion.
Inventors: |
CALDWELL; Craig S.;
(Slippery Rock, PA) ; MARSHALL; John; (Pittsburgh,
PA) ; RASILE; William F.; (Allison Park, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CALDWELL; Craig S.
MARSHALL; John
RASILE; William F. |
Slippery Rock
Pittsburgh
Allison Park |
PA
PA
PA |
US
US
US |
|
|
Assignee: |
H.J. HEINZ COMPANY
Pittsburgh
PA
|
Family ID: |
43011669 |
Appl. No.: |
13/608987 |
Filed: |
September 10, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12766091 |
Apr 23, 2010 |
|
|
|
13608987 |
|
|
|
|
61202968 |
Apr 23, 2009 |
|
|
|
Current U.S.
Class: |
426/122 ;
220/266 |
Current CPC
Class: |
B65D 2221/00 20130101;
B65D 85/72 20130101; B65D 77/2036 20130101; B65D 77/2032 20130101;
B65D 75/5855 20130101; B65D 75/563 20130101; B65D 77/204 20130101;
B65D 75/5811 20130101 |
Class at
Publication: |
426/122 ;
220/266 |
International
Class: |
B65D 77/20 20060101
B65D077/20; B65D 85/72 20060101 B65D085/72 |
Claims
1. A container comprising: a container portion fashioned from a
container material having a first bending stiffness, defining a
receptacle having a nominal volume and a spout, having a generally
planar bottom with a nominal width, having a generally planar
flange generally parallel to the planar bottom, spaced therefrom,
and surrounding the receptacle; a cover portion fashioned from a
cover material having a second bending stiffness which is less that
the first bending stiffness, the cover portion substantially
covering the generally planar flange; adhesive between the
container portion and the cover portion in the region of the
generally planar flange, such that an non-bonded region exists in
alignment with the spout; a weakened region in general transverse
alignment with the spout; and a peel initiator at the non-bonded
region.
2. The container of claim 1, further including an embossed portion
in the generally planar bottom operable to increase the bending
stiffness of that generally planar bottom.
3. The container of claim 1, including an embossed portion in the
generally planar bottom.
4. The container of claim 1, wherein the container portion and the
cover portion include a generally symmetrical pair of cuts
extending from sides of the container toward a container end so as
to define a pair of ears.
5. The container of claim 4, wherein the ears include a surface
adhering treatment.
6. The container of claim 1, wherein the container portion is
fabricated from material having an oxygen control barrier.
7. The container of claim 1, wherein the cover portion is
fabricated from a material having an oxygen control barrier.
8. The container of claim 1, wherein the peel initiator is located
in longitudinal alignment with the spout portion.
9. The container of claim 1, wherein the peel initiator is located
opposite from the spout portion.
10. The container of claim 1, wherein the weakened region includes
a pair of aligned cuts, positioned on corresponding sides of the
spout.
11. The container of claim 10, wherein the weakened region is
applied mechanically.
12. The container of claim 1, wherein the weakened region comprises
a laser score.
13. The container of claim 1, wherein the adhesive provides a
resistance to peeling in the range of about 2 to about 10 pounds
force.
14. The container of claim 1, wherein the receptacle has a width, a
depth, and a length, and is proportioned such that the depth is
less than about 50% of the width, and the depth is less than about
35% of the length.
15. The container of claim 1, wherein the container can support an
applied weight of about 50 lbs.
16. The container of claim 1, wherein the receptacle contains a
condiment.
17. The container of claim 1, wherein the receptacle contains a
condiment selected from the group consisting of ketchup,
mayonnaise, and sauce.
18. The container of claim 17, wherein the receptacle contains
ketchup.
19. The container of claim 18, wherein the first material and
second material are selected such that the condiment has a
shelf-life of at least about six months.
20. The container of claim 19, wherein shelf-life is determined
using a colorimeter operating in the L*a*b* color space, and the
L*-value does not degrade more than about 10% during a six-month
period.
21. The container of claim 1, wherein the cover portion includes a
foil layer.
22. The container of claim 1, wherein the cover portion and the
container portion are opaque.
23. The container of claim 1, where in the material of the cover
portion is selected from the group consisting of PET, APET, OPET,
MET-PET, PE, LDPE, LLDPE, mLLDPE, HDPE, mPE, EVA, PP, mOPP, PS,
HIPS, foil, EVOH, polyamide, Nylon, PVC, biaxially oriented
materials, materials complying with 21 C.F.R. Part 177, and
combinations thereof.
24. The container of claim 22, wherein the cover portion includes
at least two layers, at least one layer selected from the group
consisting of PET, APET, OPET, MET-PET, PE, LDPE, LLDPE, mLLDPE,
HDPE, mPE, EVA, PP, mOPP, PS, HIPS, foil, EVOH, polyamide, Nylon,
PVC, biaxially oriented materials, materials complying with 21
C.F.R. Part 177, and combinations thereof.
25. The container of claim 1, wherein the thickness of the cover
portion lies in the range of about 1 mil to about 5 mils.
26. The container of claim 1, where in the material of the
container portion is selected from the group consisting of PET,
APET, OPET, MET-PET, PE, LDPE, LLDPE, mLLDPE, HDPE, mPE, EVA, PP,
mOPP, PS, HIPS, foil, EVOH, polyamide, Nylon, PVC, biaxially
oriented materials, materials complying with 21 C.F.R. Part 177,
and combinations thereof.
27. The container of claim 25, wherein the container portion
includes at least two layers, at least one layer selected from the
group consisting of PET, APET, OPET, MET-PET, PE, LDPE, LLDPE,
mLLDPE, HDPE, mPE, EVA, PP, mOPP, PS, HIPS, foil, EVOH, polyamide,
Nylon, PVC, biaxially oriented materials, materials complying with
21 C.F.R. Part 177, and combinations thereof.
28. The container of claim 1, wherein the thickness of the
container portion lies in the range of about 3 mils to about 20
mils.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to packaging for
condiments. More particularly, the present invention concerns
condiment packaging adapted for opening in at least two different
ways.
[0002] Condiment packaging has evolved over the years, starting
with basic glass bottles and jars for display and sale of
condiments, including without limitation ketchup, mustard,
mayonnaise, sauces, and the like. That basic packaging later
included larger capacity bottles and jars, and then containers made
from synthetic plastic materials. Eventually, the packaging
concepts turned to providing packaging suitable for individual
portions of the condiments.
[0003] Individual packaging for condiments has, itself, seen
changes. At one time, the packaging was simply an empty cup that
could be filled with a condiment from a large capacity condiment
dispenser that may, for example, have included a pump or other
suitable dispensing device. For many years, condiments have been
available in individual portion packets or sachets which seal the
condiment between a pair of generally planar sheets of material.
See, for example, U.S. Pat. No. 3,315,801. One or more weakened
zone may be provided to simplify the act of opening the packet to
access the condiment contained therein.
[0004] Condiment packages having a generally rectangular receptacle
portion covered with a substantially planar sheet have been long
known also. See, for example, U.S. Pat. No. 2,705,579. Such
condiment packages were later provided with breakaway corners and
exposed corners for the covering material, thereby providing
different access means for the condiment packaged therein. See, for
example, U.S. Patent Application Publication Nos. 2003/0183637, and
2002/0100760.
[0005] Packages for varied products are also known where the
receptacle portion has a generally frustoconical shape with a spout
at one side. See, for example, U.S. Pat. Nos. 2,898,003, 3,660,960,
and 4,863,036. Typically, receptacles having this configuration
have been used for relatively low viscosity products such as milk
and cream.
[0006] Squeezable packages for products are also known where the
package has a spout at one end and the forming materials are
weakened in the vicinity of the spout to permit access to the
contents thereof. See for example, U.S. Pat. Nos. 5,529,224,
4,921,137, and WO 2007/126817.
[0007] Containers for liquids have also been proposed which permit
dual access modes. For example, one mode allowing squeezing for
product removal and another mode allowing dipping for product
removal. See, for example, U.S. Patent Application Publication No.
2006/0278562 (commonly owned, the entire contents of which are
incorporated herein by this reference thereto). It has been
proposed to use different opening methods where the product has
different consistencies. See, for example, Fr. Patent No.
2,801,570. Moreover, various designs for containers which permit
the varied kinds of access have also been disclosed. See, for
example, U.S. Patent Application Publication No. 2007/0164045.
[0008] Notwithstanding the development of condiment containers, a
number of difficulties are known to exist with available
containers. More particularly, during use, the containers tend to
be messy making them imperfect for use by children, and for use in
vehicles when provided at drive-thru food sources. In addition, in
recognition of environmental concerns, some retailers impose
restrictions on the types of materials that may be used in products
sold or otherwise provided through their retail outlets. When
dealing with individual portion sizes of condiments, shelf-life
stability for the condiments therein becomes important to maintain
wholesomeness of the condiments. That stability may result from a
variety of factors including for example permeability of container
materials to oxygen.
SUMMARY OF SELECTED ASPECTS OF THE INVENTION
[0009] For purposes of this invention, the word "condiment" should
be interpreted broadly so as to include substances used to enhance
larger food portions. Thus, as used in this application,
"condiment" is intended to cover traditional condiments such as
ketchup, mustard, mayonnaise, tartar sauce, and the like, as well
as to encompass, without limitation, other comestibles such as
sauces, jellies, jams, honey, and the like.
[0010] The improved condiment container according to this invention
includes a cover portion and a container portion. The container
portion preferably includes a receptacle proportioned to receive a
predetermined volume of a condiment. Typically, the predetermined
volume corresponds to the quantity of the condiment that a consumer
may personally use during consumption of a meal.
[0011] Preferably, the receptacle of the container portion includes
a generally planar bottom surface with a nominal length and a
nominal width. The bottom surface provides a stable surface to
support the condiment container during certain aspects of its use
by a consumer. The receptacle also has a nominal depth selected in
relation to the nominal width and nominal length to provide a
receptacle that is low, wide, and stable against lateral tipping
when a food item is thrust or poked into the receptacle.
[0012] The container portion preferably includes a flange extending
substantially continuously around the receptacle. Preferably, the
flange is generally planar, is spaced from the generally planar
bottom surface, and parallel thereto. At one side of the receptacle
and at the position of the flange, a spout is provided. The spout
has cross-sectional area which is smaller than the cross-sectional
area of the opening at the upper edge of the receptacle. In this
manner, access to the condiment through the spout is much more
restricted that access to the condiment through the upper edge of
the receptacle.
[0013] Preferably, the container portion is fashioned from a
material having a first bending stiffness sufficient that the
receptacle retains its shape, even in the absence of the cover
portion. Moreover, that first bending stiffness is also sufficient
to ensure that the flange will retain its shape and orientation
relative to the receptacle, even in the absence of the cover
portion. To this end, container portion may be fabricated from a
material selected from the group consisting of polyethylene
terephthalate (PET), amorphous polyethylene terephthalate (APET),
oriented polyethylene terephthalate (OPET), metalized polyethylene
terephthalate (MET-PET), polyethylene (PE), low density
polyethylene (LDPE), linear low density polyethylene (LLDPE),
metalocene linear low density polyethylene (mLLDPE), high density
polyethylene (HDPE), metalocene polyethylene (mPE), ethylene vinyl
acetate (EVA), polypropylene (PP), metalized oriented polypropylene
(mOPP), polystyrene (PS), high impact polystyrene (HIPS), foil,
ethylene vinyl alcohol (EVOH), polyamide, Nylon, polyvinyl chloride
(PVC), biaxially oriented materials, materials complying with 21
C.F.R. Part 177, and combinations thereof. While the container
portion may comprise a single layer of material, the container
portion may also be fabricated of multiple layers bonded,
coextruded or otherwise formed together into a cohesive structure,
where one or more of the layers is selected from the group of
materials set forth above. Regardless of the particular composition
used for the lid portion, all surfaces of the lid portion which
face the receptacle are required to be food-safe.
[0014] The thickness of the container portion may preferably lie in
the range of about 3 mils to about 20 mils--a mil being 0.001
inches. Depending upon the particular material and the thickness
selected, it may also be desirable to further stiffen the bottom
surface of the receptacle. Such stiffening may be accomplished by
embossing a three-dimensional pattern into the bottom surface,
thereby increasing its bending stiffness. A logo may be used to
provide that three-dimensional pattern, if desired.
[0015] The cover portion is substantially planar and preferably is
configured to have a perimeter substantially the same as the
perimeter of the container portion. Moreover, the cover portion
substantially covers the flange of the container portion. The cover
portion, however, is preferably fabricated from a material having a
second bending stiffness, where the bending stiffness of the cover
portion is lower than the bending stiffness of the container
portion. This difference in stiffness causes the cover portion to
be more flexible and more readily separable from the container
portion along the flange.
[0016] The material from which the cover portion is fabricated may
be the same as, or different from, the material used for the
container portion. Accordingly, the material of the cover portion
may be selected from the group consisting of PET, APET, OPET,
MET-PET, PE, LDPE, LLDPE, mLLDPE, HDPE, mPE, EVA, PP, mOPP, PS,
HIPS, foil, EVOH, polyamide, Nylon, PVC, biaxially oriented
materials, materials complying with 21 C.F.R. Part 177, and
combinations thereof. Typically, the thickness of the cover portion
will lie in the range of about 1 mil to about 5 mils. While the
cover portion may comprise a single layer of material, the cover
portion may also be fabricated of multiple layers bonded,
co-extruded or otherwise formed together into a cohesive structure,
where one or more of the layers is selected from the group of
materials set forth above. Regardless of the particular composition
used for the lid portion, all surfaces of the lid portion which
fact the receptacle are required to be food-safe.
[0017] To hold the cover portion and the container portion together
in a condiment package, an adhesive is preferably positioned
between the cover portion and the container portion, in the flange
area, and surrounding the top edge of the receptacle. The adhesive
preferably is a food-grade adhesive and may be conventionally
cured, for example, thermally, electromagnetically, or time cured.
Preferably, the adhesive is integral with the cover portion and/or
the container portion. Application of heat and pressure can be used
to cause the adhesive to bond the cover portion and/or the
container portion. Alternatively, adhesive may be applied around
the receptacle of the container portion in a separate step.
Preferably the adhesive is applied such that the adhesive defines a
non-bonded region in alignment with the spout, although the
adhesive otherwise surrounds the spout. If desired, pressure may be
applied to assure that the adhesive bonds the cover portion and the
container portion so as to define a sealed compartment defined by
the receptacle and the cover portion. Moreover, the adhesive is
applied such that an non-bonded region exists between the lid
portion and the flange of the container portion in general
alignment with the spout.
[0018] Preferably, the non-bonded region is located opposite the
spout and at the periphery of the container assembly. The
non-bonded region is operable to define a lift tab at an edge of
the lid portion. The lift tab is graspable so that it can be pulled
away from the flange of the container portion so as to expose the
receptacle and the contents thereof. Moreover, the adhesive is
applied such that a peel-initiating region, such as a substantially
angular region, partially defines an edge of the non-bonded region.
The peel-initiating region is engaged as the lid portion is pulled
by the tab from the container portion before the lid portion
engages the full linear extent of the adhesive extending from side
to side of the receptacle, and offers reduced resistance to
separation between the lid portion and the container portion of the
assembled package. For example, the required opening force may lie
in the range of 1 to 5 lbs. Depending upon the opening scheme
desired, the non-bonded region and the peel-initiator may be
positioned in alignment with the spout or on the opposite side of
the receptacle. Regardless of the position, when the lid portion is
peeled back away from the container portion, the receptacle is
exposed so as to be available for dipping a food item in the
condiment.
[0019] For access to the spout, a weakened area is preferably
positioned so as to be transverse to the spout. The weakened area
may be provided by mechanically cutting or fracturing the package
materials in the vicinity of the spout. The weakened area may be
fashioned by cutting the lid portion and the container portion so
that a pair of aligned slits straddle the spout. Alternatively, the
weakened area may be provided by laser scoring either the lid
portion or the container portion or both. The end of the assembled
container may then be broken away along the weakened area to expose
the spout. By then squeezing the assembled container, the condiment
will be released through the spout in a controlled manner.
[0020] In the assembled package, the adhesive preferably has
sufficient strength that the container will resist bursting when
subjected to a force of 50 lbs. or greater, and preferably when
subject to a force of 70 lbs. or greater.
[0021] If desired, the container assembly may be adapted for
attachment to the sidewall of a paperboard container. To this end,
a pair of slits may be provided in the container and extending
through both the lid portion and the container portion, where the
slits are symmetrically disposed and cooperate to define a pair of
ears. The ears can be bent out of the plane of the flange to define
an angular (when viewed from the side) hook. Resilience of the
materials used to fabricate the lid portion and the container
portion cooperates to pinch an edge of the paperboard container. To
further enhance the grip between the ears and an associated
paperboard container, the surface of each ear may be suitable
treated. For example, a tacky coating, or a roughened surface may
be provided for such a purpose.
[0022] If desired, either or both of the lid portion and the
container portion may include an oxygen control barrier or an
oxygen scavenger layer. Such a barrier layer can be helpful to
reduce or eliminate degradation of the condiment packaged in the
container assembly. If desired, either or both of the lid portion
and the container portion may be opaque. Opaqueness may enhance the
packaged product where exposure to light degrades the product over
time.
[0023] When the condiment packaged in the container is ketchup, the
materials for the lid portion and the container portion are
preferably selected such that the packaged condiment will have a
shelf-life of at least about six months. One technique for
evaluating shelf-life involves use of a colorimeter operating in
the L*a*b* color space. Shelf-life may be evaluated by monitoring
degradation of the color components of the packaged product
according to measurements in that color space. For example,
shelf-life may be determined by requiring that the L* and/or the
ratio of a*/b* does not degrade more than a specified amount during
the specified period, e.g., by less than 10% over a six-month
period.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Many objects and advantages of the present invention will be
apparent to those skilled in the art when this written
specification is read in conjunction with the appended drawings
wherein like reference numerals are applied to like elements and
wherein:
[0025] FIG. 1 is a perspective view of the condiment container;
[0026] FIG. 2 is an inverted perspective view of a condiment
container with the bottom surface positioned on top;
[0027] FIG. 3 is a bottom plan view of the condiment container;
[0028] FIG. 4 is a side elevational view of the condiment
container;
[0029] FIG. 5 is a top plan view of the condiment container;
[0030] FIG. 6 is an end elevational view of the condiment
container;
[0031] FIG. 7 is a top plan view of a second embodiment of the
condiment container;
[0032] FIG. 8 is a top plan view of a third embodiment of the
condiment container;
[0033] FIG. 9 is an enlarged cross-sectional view taken along the
line 9-9 of FIG. 5;
[0034] FIG. 10 is an enlarged detail view of spout end encircled
FIG. 9;
[0035] FIG. 11 depicts the condiment container opened for squeeze
application;
[0036] FIG. 12 is a cross-sectional view of the condiment container
of FIG. 1 showing access for dipping;
[0037] FIG. 13 is a perspective view of a fourth embodiment of the
condiment container viewed from the top;
[0038] FIG. 14 is a cross-sectional view of the fourth embodiment
of the condiment container taken along the line 14-14 of FIG.
13;
[0039] FIG. 15 is a perspective view of the fourth embodiment of
the condiment container;
[0040] FIG. 16 is a top plan view of a fifth embodiment of the
condiment container;
[0041] FIG. 17 is a side elevational view of the fifth embodiment
of the condiment container;
[0042] FIG. 18 depicts use of the fifth embodiment in conjunction
with a food container;
[0043] FIG. 19 is a side elevational view of FIG. 18.
[0044] FIG. 20 is a perspective view of the sixth embodiment of the
condiment container;
[0045] FIG. 21 is an inverted perspective view of a sixth
embodiment of the condiment container;
[0046] FIG. 22 is a top plan view of the sixth embodiment;
[0047] FIG. 23 is a bottom plan view of the sixth embodiment;
[0048] FIG. 24 is a side elevational view of the sixth
embodiment;
[0049] FIG. 25 is an end elevational view of the sixth
embodiment;
[0050] FIG. 26 is a cross-sectional view of the sixth embodiment
showing opening and access to the spout for squeezing; and
[0051] FIG. 27 is a cross-sectional view of the sixth embodiment
showing opening and access for dipping.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] Turning now to FIG. 1 a first embodiment of the condiment
container 20 according to this invention is adapted for marketing,
and delivery to a consumer as an individual portion of a condiment.
The condiment container 20 is formed by a container or cup portion
22 (see FIG. 2) and a lid or cover portion 24 (see FIG. 1) which
are sealed together by an adhesive along a flange 26.
[0053] The lid portion 24 is preferably fabricated from a material
selected from the group consisting of polyethylene terephthalate
(PET), amorphous polyethylene terephthalate (APET), oriented
polyethylene terephthalate (OPET), polyester (PE), low density
polyester (LDPE), linear low density polyester (LLDPE), metalocene
linear low density polyester (mLLDPE), high density polyester
(HDPE), metalocene polyester (mPE), ethylene vinyl acetate (EVA),
polypropylene (PP), high impact polystyrene (HIPS), foil, ethylene
vinyl alcohol (EVOH), polyamide, Nylon, polyvinyl chloride (PVC),
and combinations thereof. Where foil is used, that foil may be an
aluminum foil, or other metal foil. Typically, the thickness of the
lid portion 24 will lie in the range of about 1 mil to about 5
mils. More preferably, the lid portion 24 may have a thickness in
the range of about 1 mil to about 3 mils. The thickness of the lid
portion 24 is selected to be more flexible than the cup portion, to
have sufficient tensile integrity that the lid portion 24 can be
pulled away from the cup portion overcoming the tackiness of the
adhesive, and to have a surface texture that is graspable but not
too slippery. The lid portion 24 preferably has a peripheral
contour that substantially corresponds to the perimeter of the
flange 26.
[0054] While the lid portion 24 may comprise a single layer of the
selected material, the lid portion 24 may also be fabricated of
multiple layers bonded, co-extruded or otherwise formed together
into a cohesive structure, where one or more of the layers is
selected from the group of materials set forth above. Regardless of
the particular composition used for the lid portion 24, all
surfaces of the lid portion 24 which face the packaged condiment
are required to be food-safe. If the condiment to be packaged
experiences oxygen degradation over time, the lid portion 24 may
include an oxygen control layer or an oxygen scavenger layer in its
structure. One suitable material for an oxygen control layer is
EVOH which can function not only as an oxygen barrier but may also
function as a moisture barrier. Depending on the condiment, the
material from which the lid portion 24 is fabricated may be
transparent, translucent, or opaque. Moreover the material may be
colored, if desired.
[0055] While the combinations of acceptable material combinations
for the lid portion 24 is large, the following table identifies
some combinations known to be useful for the lid stock.
TABLE-US-00001 TABLE 1 Lid Stock Structures PET/foil/LDPE-based
sealant PET/foil/EVA-based sealant PET/LDPE-based sealant
OPET/PE/foil/LDPE/mLLDPE OPET/PE/foil/PE/mLLDPE Metalocene PE EVA
PET/MET-PET/EVA-based sealant
[0056] The cup portion 22 (see FIG. 2) includes a receptacle 30
which extends away from the flange 26 and includes a generally
planar bottom surface 32 which may be generally rectangular. In
addition, the receptacle 30 includes a sidewall 36 extending
between the bottom surface 32 and the flange 26. The flange 26
extends generally radially from the edge 40 (see FIG. 2) and
defines a substantial area which is exposed until the lid portion
24 is applied. In addition, one side of the receptacle may include
a generally triangular or generally trapezoidal surface 34 which is
inclined relative to the generally planar flange 26 and the bottom
surface 32. At one side of the receptacle 30 a spout 38 is
provided. Preferably, the cup portion 22 is designed so as to be
symmetrical about a longitudinal plane extending perpendicularly to
the plane of FIG. 5 and generally coincident with the line 9-9.
[0057] When the lid portion 24 is in place, that symmetry of the
cup portion 22 coupled with the inclined surface 34 and the lid
portion 24 creates a funnel or converging cross-sectional area at
the side of the receptacle so that the funnel communicates with the
spout 38. Thus, the spout 38 exhibits a cross-sectional area that
is much smaller than the area exposed at the top edge of the
receptacle 34 (see FIG. 4).
[0058] The cup portion 22 (see FIG. 3) is preferably fabricated
from a material that is more rigid than the stock from which the
lid portion is made. Thus, the bending stiffness of the cup portion
22 exceeds the bending stiffness of the lid portion 24. That
difference in stiffness makes the lid portion more readily deform
for removal and opening of the assembled container. Although the
cup portion 22 is stiffer than the lid portion 24, the cup portion
22 preferably is sufficiently pliable that it can be deflected by
squeezing with hand pressure--i.e., pressure applied by fingers of
an unaided human hand. Nevertheless, the cup portion 22 is
sufficiently stiff that it does not deform or deflect in the
absence of force. With those constraints and in the absence of the
lid portion 24, the cup portion 22 can be supported by the bottom
surface to provide a sufficiently rigid container to hold a
condiment without spilling. In this connection, the generally
planar flange 26 extending outwardly from the perimeter 40 of the
receptacle also functions to stiffen the receptacle region of the
cup portion 22.
[0059] In some applications, it may be desirable to have a bottom
surface 32 (see FIG. 4) having increased stiffness. Such an
increased stiffness may be accomplished by providing an embossed
feature 44 in the bottom surface 32. Such an embossed feature 44
may also extend onto the inclined surface 34, if desired. In some
applications, that embossed feature 44 may comprise a logo of the
manufacturer. The enhanced stiffness results from the depth of the
embossed feature 44 relative to the plane of the bottom surface
32.
[0060] In general, the material from which the cup portion 22 is
fabricated may be selected from the same group of materials
available for the lid portion 24, namely the group consisting of
PET, APET, OPET, MET-PET, PE, LDPE, LLDPE, mLLDPE, HDPE, mPE, EVA,
PP, mOPP, PS, HIPS, foil, EVOH, polyamide, Nylon, PVC, biaxially
oriented materials, materials complying with 21 C.F.R. Part 177,
and combinations thereof. Where foil is used, that foil may be an
aluminum foil, or other metal foil. Typically, the thickness of the
cup portion 22 will lie in the range of about 3 mils to about 20
mils. More preferably, the cup portion 22 may have a thickness in
the range of about 8 mils to about 12 mils. The thickness of the
cup portion 22 is selected to be less flexible than the lid portion
24 so that the lid portion 24 can be pulled away from the cup
portion 22 overcoming the tackiness of the adhesive.
[0061] As with the lid portion 24, certain combinations of the
materials for the cup portion 22 have been found to be particularly
suitable, as set forth in the table below.
TABLE-US-00002 TABLE 2 Suitable Cup Portion Material Combinations
PVC/adhesive layer/sealant film APET/adhesive layer/sealant film
APET/sealant film PP/adhesive layer/sealant film HIPS APET/EVOH
APET/PE/EVOH/PE APET/HDPE/EVOH/LDPE APET/Nylon/APET APET/Nylon/EVOH
PS/EVA/EVOH/EVA/sealant
[0062] The receptacle of the condiment container 20 is preferably
sized to contain a suitable individual serving of the condiment,
for example, a nominal volume of about one ounce. While larger and
smaller nominal volumes are within the scope of this invention, the
nominal volume will generally correspond to the quantity of the
particular condiment desired by a typical individual. As seen in
FIG. 3, the receptacle portion of the package has a nominal width
corresponding to the maximum distance between the opposed sidewalls
at the location of the edge 40 and extending transverse to the
plane of symmetry between opposed sidewalls, a nominal length being
the maximum length between sidewalls of the receptacle at the
location of the edge 40 and measured along the plane of symmetry,
and a nominal depth (see FIG. 4) also measured in the plane of
symmetry but extending from the bottom surface 32 to the flange 26.
These nominal dimensions define the nominal volumetric capacity for
the receptacle portion.
[0063] Another important feature of the cup portion 22 is lateral
stability against tipping. Furthermore these nominal dimensions can
be used to establish guidelines that provide adequate tipping
stability. More specifically, the ratio of the nominal height to
the nominal width is preferably less that about 0.5, and more
preferably less than about 0.45. In addition, the ratio of the
nominal height to the nominal length is preferably less that about
0.3, and more preferably less than about 0.26. When the receptacle
of the cup portion 22 has nominal dimensions within these ranges,
the receptacle is sufficiently stable that it does not tip when a
food item is dipped in the condiment contained therein.
[0064] The lid portion 24 and the cup portion 22 are sealed
together using a food-grade adhesive so as to define an
encapsulated volume isolated from the environment. One technique
for accomplishing the seal is to include a heat-sealable layer on
the inside of the lid portion 24 and on the inside of the cup
portion 22. Upon application of heat and pressure applied to the
flange 26, the adjacent surfaces bond together forming the
appropriate seal surrounding the periphery of the edge 40 of the
receptacle. Alternatively, a suitable food-grade adhesive
compatible with the materials of the container may be used. The
adhesive is preferably applied so as to surround the edge 40 of the
receptacle (see FIG. 3), but not so at to be contiguous
therewith--i.e., some space exists between the adhesive and the
edge 40. Moreover, the adhesive is applied so that it does not
cover the spout 38. Preferably, the condiment container is capable
of withstanding an applied force of at least about 50 lbs without
bursting or breaking through the seal. More preferably, an applied
force of about 70 lbs. will not burst the seal.
[0065] The adhesive preferably extends to the peripheral edge 50 of
the flange 26, but provides an non-bonded region 52 at one side of
the receptacle. That non-bonded region 52 extends inwardly along
the flange 26 from the peripheral edge 50 of the flange by a
distance sufficient that a pull-tab portion 54 (see FIG. 5) of the
lid portion 24 not adhesively connected to the flange 26 is
sufficiently large to be graspable between fingers. A distance of
about 0.5 inches or more is graspable for the pull-tab 54. It will
be apparent to those skilled in the art that attempting to peel a
lid portion away from the flange 26 (see FIG. 3) is difficult due
to the width of the seal. It has been found, however, that
inclusion of a generally angular feature 56 aligned with the plane
of symmetry and defining part of one edge of the non-bonded region
52 provides a peel-initiator that reduces the necessary force to
peel the lid portion away from the flange 26. Inclusion of a
peel-initiator at the edge of the non-bonded region materially
enhances the ease with which the lid portion can be removed from
the container.
[0066] From the foregoing discussion, it will be apparent to those
skilled in the art that the tab 54 can be grasped to pull the lid
portion 24 away from the flange 26 of the cup portion 22 to expose
the receptacle and its contents. Such a step would prepare the
container for dipping a food item into the condiment. However, a
different opening scheme is also available with the container of
this invention. More particularly, the container may be provided
with a weakened region in the vicinity of the spout 38 for the
purpose of opening the spout 38 as an alternative to removal of the
lid portion 24. The weakened region may, for example, comprise a
pair of aligned slits 60, 62 in the vicinity of the spout 38. The
slits 60, 62 are aligned with one another and straddle the spout
38. The slits 60, 62 may extend through the thickness of both the
lid portion 24 and the cup portion 22. With this arrangement, the
distal end of the container 20 can be bent to fracture the material
of the container and expose a channel through the spout 38 into the
receptacle. At that point application of pressure to the receptacle
will cause the condiment to be expelled through the spout 38 in
directionally controlled and defined way.
[0067] The aligned slits 60, 62 can be applied to the container
before, during, or after assembly of the condiment container 20.
However, an efficient mechanical way of creating the aligned slits
60, 62 is to form them at the same time that the lid portion 24 is
applied to the cup portion 22 and adhesively connected thereto.
Alternatively, a laser scoring process may be employed to weaken
the container around the spout 38 so that an end of the container
can be snapped or twisted off to expose the end of the spout
passage.
[0068] The materials selected for the lid portion 24, the cup
portion 22, and the adhesive are preferably chosen so that the
condiment has a desired shelf life. In the case of a condiment such
as ketchup, a shelf-life of at least six months is desirable. With
condiments like ketchup, shelf-life can be evaluated by changes in
the color characteristics of the condiment. Testing for shelf-life
can, therefore, be conducted using colorimetric analyses. The
Hunter Lab color space and the L*a*b* color space use three
coordinates to define any particular color. For example, in the
L*a*b* color space, the coordinates L*, a*, and b* define the
three-dimensional color space. The L* component measures lightness
and correlates particularly well with human eye perceptions. The L*
value ranges between 0 corresponding to pure black and 100
corresponding to pure white. The a* coordinate measures the color
position between red/magenta and green, with negative values
indicating green and positive values indicating magenta. The b*
component measures the color position between yellow and blue, with
negative values indicating blue, while positive values indicate
yellow. Accordingly, changes in ketchup color over time can be
evaluated by the value of and changes in the value of the L*, a*,
and b*, or L, a, b components. For purposes of shelf-life analysis,
it has been found that the lightness component, L* or L, provides a
reliable parameter to correlate with shelf-life. More particularly,
as long as the L* component value remains within about 10% of its
initial value, during the shelf-life, the shelf-life requirement is
satisfied. In addition, the ratio of a*/b* or a/b is also
indicative of product degradation. Thus, in some instances,
satisfactory shelf-life may be determined when the L* (or L)
component and the a*/b* (or a/b) ratio remain within about 10% of
their initial values, respectively. Other condiments for which
color changes over time can also be colorimetrically evaluated for
shelf-life using one or more of the L*a*b* color space
components.
[0069] An alternative embodiment of the invention is shown in FIG.
7. In this arrangement, the peel initiator 56' and the adjacent
seal portion are constructed such that the peel-initiator blends to
a seal presenting a gradually increasing resistance, as opposed to
the step-wise increasing resistance of the first embodiment. This
arrangement is characterized by the angularly converging portions
of the seal that terminates with the peel-initiator 56'.
[0070] Yet another embodiment of the invention includes a pair of
peel-initiator structures in the adhesive bonding between the lid
portion 24 and the cup portion (see FIG. 8). In this arrangement, a
peel initiator 64, 66 is provided at corresponding corners of the
adhesive seal. With this arrangement, the lid portion 24 may be
peeled away from either corner with a corresponding reduction in
the force needed to initiate the peel-away.
[0071] To assemble the condiment container 20, the cup portion 22
may be exposed to a dispensing mechanism that deposits a metered
volume of condiment 70 (see FIG. 9) in the receptacle. The metered
volume supplied is less than the actual volume of the receptacle so
that some head space exists above the condiment. After the adhesive
is applied to the flange 26, the lid portion 24 is positioned in
overlying relationship to the cup portion 22 and sealed thereto.
The resulting structure includes an adhesive 72 bonding the lid
portion 24 and the cup portion 22 (see FIG. 10).
[0072] In another embodiment of the condiment container 20 (see
FIG. 7), the non-bonded region 54 may be enlarged insofar as its
width in the direction of the plane of symmetry is concerned. Other
than the peel-initiator 56' and associated structure, the condiment
container 20 of this embodiment has the same features and
characteristics as the embodiment described above in connection
with FIGS. 1-6. Accordingly, those common features will not be
repeated here. The peel-initiator 56' of this second embodiment
extends farther into the region 54 than in the first embodiment
while the adhesive seal 70 has a substantially uniform width around
the edge of the receptacle. Here, the peel-initiator 56' is shaped
substantially as a chevron, caret, or curly bracket. Moreover, the
peel-initiator 56' is positioned in general longitudinal alignment
with the spout 38 but is located on the opposite side of the
receptacle from the spout 38. With such an arrangement, the
alternative structures for opening the package are separated from
one another so that the user or consumer makes a conscious decision
as to whether to open the condiment container by breaking or
tearing open the spout 38 for a squeeze application, or to peel
back the lid portion 24 so that the container 20 can be used for a
dipping application.
[0073] In a further embodiment (see FIG. 8), the condiment
container 20 has a different position and arrangement for the
peel-initiator but is otherwise fully described by the discussion
above in connection with FIGS. 1-6, which discussion will not be
repeated here. In this further embodiment, a pair of
peel-initiators 64, 66 are provided, and each peel-initiator 64, 66
is positioned at a corresponding corner of adhesive seal 70
generally aligned with a corner of the receptacle. Recognizing that
some consumers may find it easier, or more intuitive to start
peeling back the lid portion 24 from a corner, the corner location
of the peel initiators 64, 66 facilitates the peel opening. As
shown, the peel-initiators 64, 66 are symmetric with respect to the
plane of symmetry for the condiment container so that either corner
may be randomly chosen by the consumer or user to start the peel
opening process.
[0074] It is also within the purview of this disclosure that only
one peel-initiator be used and that that peel-initiator be located
at a corner of the condiment container offset from the plane of
symmetry. Such a container may look like the embodiment of FIG. 8
but with only one of the peel-initiators 64, 66 being present. It
is likely that with such an embodiment directions might be provided
on the outside surface of the lid portion 24 focusing consumer
attention on the appropriate corner for peel initiation.
Alternatively, the cup portion 22 and the lid portion 24 could be
trimmed more closely to the adhesive line at one corner, leaving a
tab projecting from the other corner and the peel-initiator so that
peel-type opening would necessarily occur at the peel-initiator,
whether it is centrally positioned or arranged at that other corner
of the container. Here again, the features of such a condiment
container are adequately described above in connection with FIGS.
1-6 and will not be repeated here.
[0075] To use the condiment container 20, (see FIG. 11), the
consumer initially decides whether to have controlled dispensing of
the condiment or to have full access to the receptacle. Where
controlled dispensing is desired, the end of the container is
broken off or twisted off at the location of the weakened area to
expose the end of the spout 38. By applying finger pressure to the
receptacle area, condiment is squeezed out of the spout so that it
can be applied selectively, directionally, and in a controlled
manner to a food item. Where fuller access to the condiment is
desired (see FIG. 12), the tab 54 may be pulled away from the
flange, past the peel-initiator, and away from the upper edge of
the receptacle to expose as much (or all) of the receptacle as may
be desired.
[0076] Yet another embodiment of the condiment container 20 (see
FIG. 13) has a different position for the peel-initiator 84. The
features of this condiment container not specifically described are
adequately described in connection with FIGS. 1-6 and will not be
repeated here. In this arrangement, the peel initiator 84 is
aligned with the spout 38 and positioned so that the spout 38 is
between the peel initiator 84 and the receptacle of the cup portion
22 (see FIG. 14). Here, the flange 26 of the cup portion 22
includes a tongue 80, which may be generally rectangular,
symmetrically disposed with respect to the spout 38 and extending
beyond the spout. The peel-initiator 84 may have a generally
angular or generally pointed feature oriented outwardly away from
the spout 38 and the receptacle, but in general alignment
therewith. Preferably, the tongue 80 extends beyond the
peel-initiator 84 by a distance of 0.5 inches or more. The lid
portion 24 (see FIG. 13) also includes a tongue 82 adapted, sized,
and arranged to overlie and conform to the tongue 80 of the cup
portion.
[0077] To open the condiment container 20, the tongue 86 of the lid
portion 22 (see FIG. 14) is grasped and peeled away from the tongue
80 of the cup portion 22, for example in the direction of arrow 86.
After the separation begins at the peel-initiator 84, the tongue 82
of the lid portion 22 exposes the end of the spout 38. At this
point, the condiment container 20 may be squeezed by the user so
that condiment is expressed through spout 38 in a controlled and
readily directed manner. Rather than stopping when the spout is
exposed, the lid portion 24 may be peeled farther away from the
tongue 80 of the cup portion 22 to expose a portion or all of the
receptacle and the condiment 70 therein. Thus, the container 20 can
provide a dipping container for a food item. It will be apparent to
those skilled in the art that it is not required that the lid
portion either open the spout or open the receptacle. If desired,
the consumer may first open the spout and dispense some of the
condiment therethrough, and later open the lid portion to expose
the receptacle to use some of the condiment by dipping. Moreover,
if desired, the lid portion may be partially opened or completely
removed.
[0078] Another embodiment of the condiment container 20 (see FIG.
16) may have the spout 38 located at one end with the graspable
tongue extending in a generally triangular configuration beyond the
spout 38. The features of this condiment container not specifically
described are adequately described in connection with FIGS. 1-6 and
will not be repeated here. This embodiment also includes a
generally pentagonal receptacle 90, but with sides meeting at
obtuse angles. One end of the container has a generally straight
edge 91 extending generally perpendicularly to the plane of
symmetry for the container 20, and having a length corresponding to
the maximum width of the container 20. The container also includes
side edges 93, 95 extending from corresponding ends of the straight
edge 91 to corresponding corners of the container. A pair of
symmetrically disposed slits 92, 94 extend from the corresponding
side edge 93, 95 toward the straight edge 91, but do not intersect
that straight edge 91. The slits 92, 94 may be straight or arcuate,
as desired, but the blind end of each slit 92, 94 is spaced from
the straight edge 91 as well as from both side edges 93, 95. With
that arrangement, the slits 92, 94, and the side edges 93, 95
cooperate to define a pair of symmetrically disposed ears 96, 98.
At the time of manufacture, the ears 96, 98 lie in the plane of the
flange 26 (see FIG. 17).
[0079] In use, the condiment container 20 of this embodiment
provides an additional convenience feature (see FIG. 18). The ears
96, 98 may be pushed out of the plane of the flange 26 so that an
upper edge of a package 100 can be received between the ears 96, 98
and the flange 26. In this fashion, the condiment package 20 can be
dispensed with the package 100 where appropriate. The condiment
container 20 can be configured for opening a described above in any
of the other embodiments. Moreover, when opened for dipping use
(see FIG. 19), the cooperation between the ears 96, 98 and the side
of the package 100 will support the condiment container 20 in
cantilevered position so that the condiment is readily
accessible.
[0080] If desired, the surface of each ear 96, 98 may be treated to
enhance frictional engagement with a package 100. For example, the
surface of the ears 96, 98 could be roughened relative to other
surfaces of the container 20, or may have a low tack adhesive
applied to at least a portion thereof.
[0081] The shape of the receptacle in the cup portion may be
generally generally pentagonal as depicted in the embodiments
described above, but may also have other desired shapes. For
example, generally rectangular, generally square, generally
triangular, generally polygonal, oblong, generally elliptical, and
other shapes for the receptacle are all within the scope of this
disclosure. For example, another embodiment of the condiment
container 20 may include a generally cylindrical receptacle 110
(see FIG. 4A). The features of this condiment container not
specifically described are adequately described in connection with
FIGS. 1-6 and will not be repeated here. As seen from the various
embodiments shown and described in this disclosure, the flange 26
surrounding the receptacle may follow the shape of the upper edge
of the receptacle, or may have a larger area. In FIG. 21, for
example, the flange 26 is generally rectangular thereby providing
multiple locations from which the lid portion can be peeled back,
some of which access the spout and some of which access the
receptacle.
[0082] To make a container in accordance with this disclosure, the
material for the cup portion is typically provided in a roll. That
roll of material is unwound into a forming device as a
substantially continuous sheet where a plurality of receptacles are
formed. Typically, the receptacles may be formed in a row having
two to about twelve or more receptacles therein, thereby forming a
sheet with receptacles in straight transverse rows and straight
longitudinally extending rows running in the direction of the
length of the sheet unwound from the roll.
[0083] The sheet with formed receptacles then advances to filling
apparatus. In that filling apparatus, the desired condiment is
deposited in the receptacles through a conventional metering device
to control the quantity and volume of condiment for each
receptacle. Ordinarily, there is a filling head for each
longitudinal row of receptacles in the sheet. Moreover, these
filling heads may supply the same condiment in each of the
longitudinal rows. However, if desired, it is within the scope of
this disclosure that adjacent fill heads may deliver different
condiments so that different condiments are filled in the
receptacles of adjacent longitudinal rows of the sheet.
[0084] Next, the sheet with filled receptacles is flushed with gas
compatible with the product and helpful in retarding product
degradation. At this point a second sheet of material for the lid
portion is unrolled and advanced into overlying relationship with
the receptacle sheet where it is sealed into position with respect
to each of the receptacles.
[0085] The filled, covered, receptacles in the substantially
continuous sheet then advance to a die cutting machine where
individual containers are cut from the continuous sheet.
Conventional accumulation, packaging, palletizing, storing, and
shipping of the individual containers then occurs.
[0086] The word "about" is used in connection with numerical values
at various locations throughout this specification with the intent
of avoiding mathematical precision for those numerical values.
Accordingly, when the word "about" is used in connection with a
numerical value or range of values, it is intended that the word
"about" should be interpreted as including a tolerance of .+-.10%
around the stated numerical value. To similar effect, the words
"generally" and "substantially" are used throughout this
specification in connection with various geometric words, terms,
and/or phrases. The intent of the words "generally" and
"substantially" in such a context is to avoid strict geometrical
definitions, to encompass structures which approximate the
geometrical definitions, and to include features that are not
precisely met by the related terms and/or phrases.
[0087] Moreover, it is expressly intended that this invention be
interpreted so as to be consistent with all parts of this
specification. Thus, the summary, abstract, drawing description,
and the like are not intended to be limiting but are intended to
summarize some, but not all, features, or to provide an overview of
the entire specification, or of a particular drawing.
[0088] It will now be apparent to those skilled in the art that
this specification describes a new, useful, and nonobvious
condiment container. Moreover, it will be apparent to those skilled
in the art that numerous modifications, variations, substitutions,
and equivalents exist for the various features of the invention
described in the appended claims. Accordingly, it is expressly
intended that all such modifications, variations, substitutions,
and equivalents which fall within the spirit and scope of the
invention, as defined in the appended claims, be embraced
thereby.
* * * * *