U.S. patent application number 14/098915 was filed with the patent office on 2014-06-12 for container with removable portion.
This patent application is currently assigned to 2266170 Ontario Inc.. The applicant listed for this patent is 2266170 Ontario Inc.. Invention is credited to YuCheng Fu, Liberatore A. Trombetta.
Application Number | 20140161936 14/098915 |
Document ID | / |
Family ID | 50881209 |
Filed Date | 2014-06-12 |
United States Patent
Application |
20140161936 |
Kind Code |
A1 |
Trombetta; Liberatore A. ;
et al. |
June 12, 2014 |
Container WIth Removable Portion
Abstract
A container is provided with a body defining an interior space
having an opening. A filter is disposed in the body to define an
ingredients chamber. Ingredients are disposed in the ingredients
chamber and a cover is disposed over the opening to seal the
interior space. The container is adapted to allow cover and filter
with ingredients contained in ingredients chamber to be separated
from the remainder of body.
Inventors: |
Trombetta; Liberatore A.;
(Ancaster, CA) ; Fu; YuCheng; (Mississauga,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
2266170 Ontario Inc. |
Mississauga |
|
CA |
|
|
Assignee: |
2266170 Ontario Inc.
Mississauga
CA
|
Family ID: |
50881209 |
Appl. No.: |
14/098915 |
Filed: |
December 6, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61734667 |
Dec 7, 2012 |
|
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|
61760880 |
Feb 5, 2013 |
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Current U.S.
Class: |
426/77 |
Current CPC
Class: |
B65D 85/8043 20130101;
B65D 85/816 20130101; B65D 2565/385 20130101; B65D 85/8046
20130101 |
Class at
Publication: |
426/77 |
International
Class: |
B65D 85/804 20060101
B65D085/804 |
Claims
1. A container comprising: a body defining an interior space having
an opening; a filter disposed in said interior space to define an
ingredients chamber, said filter being bonded to said body with a
first bond, said first bond being a peelable bond; ingredients
disposed in said ingredients chamber; a cover disposed over said
opening for covering said interior space, said cover being bonded
to said filter at a periphery to said opening with a second bond;
wherein said cover is adapted to be removed together with said
filter upon the application of sufficient force by hand following
use of the container.
2. A container as claimed in claim 1, further including a tab
adapted for providing a grip to remove said cover with said filter
and said ingredients chamber from said body.
3. A container as claimed in claim 1, wherein a notch is defined in
the interior surface of said body, said notch providing a predicted
point of weakness in said body.
4. A container as claimed in claim 3 wherein said notch extends
substantially about the periphery of said opening.
5. A container as claimed in claim 3 wherein said body is formed of
a multilayered material that includes a barrier layer disposed
between a sealing layer and an outer layer, and wherein said notch
is defined in said sealing layer.
6. A container as claimed in claim 1, wherein said filter has a
basis weight in the range of 8 to 400 gsm.
7. A container as claimed in claim 2, wherein said tab is formed
from said cover.
8. A container as claimed in claim 2, wherein said tab is formed
from a portion of said body defined by a separation point at a
location where said filter is bonded to said body.
9. A container as claimed in claim 8, wherein said separation point
is defined in said flange of said body to define said tab.
10. A container as claimed in claim 1 wherein said first bond is
formed with a first bonding material disposed between a first
surface of said filter and a first surface of said body.
11. A container as claimed in claim 1, wherein said body is formed
of a multilayered material that includes a barrier layer disposed
between a sealing layer and an outer layer, and wherein said first
bond between said filter and said body is formed with said sealing
layer.
12. A container comprising: a body defining an interior space
having an opening, said body having a flange surrounding said
opening; a filter disposed in said body to define an ingredients
chamber, said filter being bonded to a first surface of said flange
with a first bond, said first bond being a peelable bond; a
separation point defined in said flange, said separation point
defining a tab that is adapted to be separated from the remainder
of said flange upon the application of sufficient force by hand;
ingredients disposed in said ingredients chamber; a cover disposed
over said opening for covering said interior space, said cover
being bonded to said filter with a second bond, wherein said tab
and said cover is adapted to be removed together with said filter
and said ingredients chamber containing said ingredients following
use of the container by the application of force by hand.
13. A container as claimed in claim 12, wherein said flange has a
uniform width.
14. A container as claimed in claim 12, further comprising a tab
indicator disposed on the exterior of said body to indicate the
location of said tab.
15. A container as claimed in claim 12, wherein a notch is defined
in the interior surface of said body, said notch providing a
predicted point of weakness in said body.
16. A container as claimed in claim 15 wherein said notch extends
substantially about the periphery of said opening.
17. A container as claimed in claim 15 wherein said body is formed
of a multilayered material that includes a barrier layer disposed
between a sealing layer and an outer layer, and wherein said notch
is defined in said sealing layer.
18. A container as claimed in claim 12, wherein said body is formed
of a multilayered material that includes a barrier layer disposed
between a sealing layer and an outer layer, and wherein said first
bond between said filter and said body is formed with said sealing
layer.
19. A container comprising: a body defining an interior space
having an opening, said body having a flange surrounding said
opening; a separation point defined in said flange, said separation
point defining a tab that is adapted to be separated from the
remainder of said flange upon the application of sufficient force
by hand; ingredients disposed in said ingredients chamber; a cover
disposed over said opening for sealing said interior space, said
cover being bonded to said flange with a peelable bond; wherein
said cover is adapted to be removed by the application of
sufficient force by hand to separate said tab and peel said cover
from the remainder of said flange.
20. A container as claimed in claim 19, wherein said flange has a
uniform width.
21. A container as claimed in claim 19, further comprising a tab
indicator disposed on the exterior of said body to indicate the
location of said tab.
22. A container as claimed in claim 19, wherein a notch is defined
in the interior surface of said body, said notch providing a
predicted point of weakness in said body.
23. A container as claimed in claim 22 wherein said notch extends
substantially about the periphery of said opening.
24. A container as claimed in claim 22 wherein said body is formed
of a multilayered material that includes a barrier layer disposed
between a sealing layer and an outer layer, and wherein said notch
is defined in said sealing layer.
25. A container as claimed in claim 19, wherein said body is formed
of a multilayered material that includes a barrier layer disposed
between a sealing layer and an outer layer, and wherein said first
bond between said filter and said body is formed with said sealing
layer.
26. A container comprising: a body defining an interior space
having an opening, said body having a flange surrounding said
opening; a separation point defined in said body around its
circumference at a desired location for separating one portion of
said body from the remainder of said body, ingredients disposed in
said ingredients chamber; a cover disposed over said opening for
covering said interior space; wherein said separation point is
adapted to provide a point of separation under the application of
sufficient force to separate a portion of said body, including said
flange with said cover, from the remainder of said body.
27. A container as claimed in claim 6, wherein said force is an
opposing twisting force applied to said flange and the remainder of
said body.
Description
FIELD
[0001] This specification relates to containers and in particular
to a container, such as a single serve capsule, having a portion
that is removable from the remainder of the container.
BACKGROUND
[0002] The following background discussion is not an admission that
anything discussed below is citable as prior art or common general
knowledge. The documents listed below are incorporated herein in
their entirety by this reference to them.
[0003] Single serve capsules for use in machines for preparing
beverages or other products are becoming increasingly popular. Such
capsules come in a variety of formats for producing products such
as espresso coffee, drip coffee, tea or hot chocolate.
[0004] Multi chamber capsules, such as drip coffee capsules, have a
first chamber defined by a filter (typically a paper filter) that
is loosely packed with ingredients (such as ground coffee) and a
second chamber downstream of the first chamber that defines an
empty space for receiving a prepared product that flows through the
filter prior to dispensing into a cup. One example of a multi
chamber capsule is the Keurig K-Cup.TM. capsule. This capsule
includes a paper filter having a side wall that is sealed to an
inside peripheral edge of the capsule.
[0005] A problem with conventional multi chamber capsules, such as
the Keurig K-Cup.TM. capsule, is that the capsules are not adapted
for recycling. The portion containing the precursor ingredients
(such as coffee grounds) cannot be easily separated from the
plastic outer shell. As a result, the used capsules must be
disposed into garbage destined for landfill.
[0006] One approach to addressing this problem is provided with the
Keurig Vue.TM. capsule, as described in US patent application
2012/0058226 the subject matter of which is incorporated in its
entirety herein by reference. The Vue.TM. capsule includes a filter
that is secured to the capsule cover inwardly from the sidewall of
the outer shell. The capsule cover with attached filter may be
peeled from the outer shell to allow the shell to be disposed into
plastics recycling while the cover and filter (with ingredients) is
disposed into garbage destined for landfill. As a result, the
Vue.TM. capsule provides a partially recyclable solution.
[0007] There are a number of problems with the Keurig Vue.TM.
capsule solution however. The process for filling and sealing the
capsule is more complicated than for conventional capsules and the
capsule is more costly to produce as a result. Also, the used paper
filter is weak, in particular when it is wet, and prone to tearing
and spilling of ingredients when the filter and cover are being
removed from the capsule following use.
[0008] Other forms of containers having a removable portion are
also well known. Such containers typically include a component that
is adapted to be manipulated by a user to facilitate removal of the
desired portion of the container. A problem with such containers is
that the component tends to add complexity and cost to the
manufacturing and packaging of the container. Another problem with
such containers is that they are not adapted to include a filter
element that is removable.
[0009] There is a need for an improved container having one or more
removable portions that address one or more problems with
conventional containers such as the problems noted above.
SUMMARY
[0010] In one aspect the invention provides a container comprising:
a body defining an interior space having an opening;
a filter disposed in said interior space to define an ingredients
chamber, said filter being bonded to said body with a first bond,
said first bond being a peelable bond; ingredients disposed in said
ingredients chamber; a cover disposed over said opening for
covering said interior space, said cover being bonded to said
filter at a periphery to said opening with a second bond; wherein
said cover is adapted to be removed together with said filter upon
the application of sufficient force by hand following use of the
container.
[0011] In another aspect the invention provides a container
comprising:
a body defining an interior space having an opening, said body
having a flange surrounding said opening; a filter disposed in said
body to define an ingredients chamber, said filter being bonded to
a first surface of said flange with a first bond, said first bond
being a peelable bond; a separation point defined in said flange,
said separation point defining a tab that is adapted to be
separated from the remainder of said flange upon the application of
sufficient force by hand; ingredients disposed in said ingredients
chamber; a cover disposed over said opening for covering said
interior space, said cover being bonded to said filter with a
second bond, wherein said tab and said cover is adapted to be
removed together with said filter and said ingredients chamber
containing said ingredients following use of the container by the
application of force by hand.
[0012] In another aspect the invention provides a container
comprising:
a body defining an interior space having an opening, said body
having a flange surrounding said opening; a separation point
defined in said flange, said separation point defining a tab that
is adapted to be separated from the remainder of said flange upon
the application of sufficient force by hand; ingredients disposed
in said ingredients chamber; a cover disposed over said opening for
sealing said interior space, said cover being bonded to said flange
with a peelable bond; wherein said cover is adapted to be removed
by the application of sufficient force by hand to separate said tab
and peel said cover from the remainder of said flange.
[0013] In another aspect the invention provides a container
comprising:
a body defining an interior space having an opening, said body
having a flange surrounding said opening; a separation point
defined in said body around its circumference at a desired location
for separating one portion of said body from the remainder of said
body, ingredients disposed in said ingredients chamber; a cover
disposed over said opening for covering said interior space;
wherein said separation point is adapted to provide a point of
separation under the application of sufficient force to separate a
portion of said body, including said flange with said cover, from
the remainder of said body.
[0014] Other aspects and features of the teachings disclosed herein
will become apparent, to those ordinarily skilled in the art, upon
review of the following description of the specific examples of the
specification.
DRAWINGS
[0015] The drawings included herewith are for illustrating various
examples of articles, methods, and apparatuses of the present
specification and are not intended to limit the scope of what is
taught in any way. For simplicity and clarity of illustration,
where considered appropriate, reference numerals may be repeated
among the drawings to indicate corresponding or analogous
elements.
[0016] FIG. 1 is a perspective view of a container in accordance
with the present invention;
[0017] FIG. 2 is a perspective view of the container of FIG. 1
following its use in a machine for preparing products from
containers, the cover and filter being partially removed from the
body;
[0018] FIG. 3 is a sectional view of the container of FIG. 1 as
viewed along lines 3-3, the container being disposed in a chamber
for a machine for preparing a product from the container;
[0019] FIG. 4 is an enlarged sectional view of the container shown
in FIG. 3 as viewed within circle 4;
[0020] FIG. 5 is an exploded sectional view of a container in
accordance with another embodiment of the present invention, the
container having a body and cover made from multilayered
materials;
[0021] FIGS. 6 (a) to 6 (d) are enlarged sectional views of a
container in accordance with another embodiment of the present
invention showing different examples of a peelable bond between
filter and body;
[0022] FIG. 7 is a perspective view of another embodiment of a
container in accordance with the present invention, showing the
filter being peeled from the body and the cover being peeled from
the filter;
[0023] FIG. 8 is a perspective view of another embodiment of a
container in accordance with the present invention, showing the
filter attached to the sidewall of the body with a tab for peeling
filter from body and the cover attached to the flange with a tab
for peeling cover from body;
[0024] FIG. 9 is a side view of a container in accordance with
another embodiment of the present invention with a portion of the
container being separated from the remainder of the container;
[0025] FIG. 10 is a top view of the body for the container of FIG.
9 showing one variant for the separation point;
[0026] FIG. 11 is a top view of the body for the container of FIG.
9 showing another variant for the separation point;
[0027] FIG. 12 is a side view of a container in accordance with
another embodiment of the present invention showing the tab, cover
and filter with ingredients being separated from the remainder of
the body;
[0028] FIG. 13 is a bottom view of the container shown in FIG. 12
with the separation point defined in the bottom surface of flange
to define tab;
[0029] FIG. 14 is a schematic top view of a mold and material for
forming a plurality of bodies with a plurality of tab indicators in
accordance with the present invention
[0030] FIG. 15 is a perspective view of another embodiment of a
container in accordance with the present invention, showing the
cover and filter being peeled from the body;
[0031] FIG. 16 is an enlarged sectional view of the flange for the
container of FIG. 15 as viewed along lines 16-16, showing the
separation point defining the tab prior to it being separated from
the remainder of the flange (the cover is not shown);
[0032] FIG. 17 is a perspective view of another embodiment of a
container in accordance with the present invention;
[0033] FIG. 18 is a perspective view of another embodiment of a
container in accordance with the present invention;
[0034] FIG. 19 is a perspective view of another embodiment of a
container in accordance with the present invention;
[0035] FIG. 20 is a perspective view of another embodiment of a
container in accordance with the present invention.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0036] Various apparatuses or methods will be described below to
provide examples of the claimed invention. The claimed invention is
not limited to apparatuses or methods having all of the features of
any one apparatus or method described below or to features common
to multiple or all of the apparatuses described below. The claimed
invention may reside in a combination or sub-combination of the
apparatus elements or method steps described below. It is possible
that an apparatus or method described below is not an example of
the claimed invention. The applicant(s), inventor(s) and/or
owner(s) reserve all rights in any invention disclosed in an
apparatus or method described below that is not claimed in this
document and do not abandon, disclaim or dedicate to the public any
such invention by its disclosure in this document.
[0037] A container in accordance with one embodiment of the present
invention is shown generally at 10 in FIGS. 1-4. Container 10
includes a body 12, filter 14, ingredients 16 and cover 18.
[0038] Body 12 includes a side wall 20 and an end wall 22 together
defining an enclosed interior space 24. An opening 26 is defined at
one end of body 12. Body 12 further includes a flange 28 that
extends around the perimeter of opening 26. Preferably, side wall
20, end wall 22 and flange 26 are all integrally formed, such as by
thermoforming, from one sheet of material. Container 10 preferably
is symmetrical with an annular flange 28 having a uniform width W.
Most preferably, container 10 has a circular cross section in order
that it does not require orientation during manufacture or during
use (in cases where container is used in a machine for preparing
beverages or other products).
[0039] Cover 18 includes at least one tab 30 that is adapted to
provide a grip for cover 18 to be peeled from body 12 following use
of container 10 in a machine for preparing products, such as
beverages, from containers 10. Tab 30 may extend from flange 28 and
fold over or, more preferably, tab 30 is integrally formed with
flange 28 as shown for example with the embodiment depicted in
FIGS. 12 and 13.
[0040] Cover 18 is preferably formed of a material that is
resistant to tearing upon the application of a peel force. Most
preferably, cover 18 is formed of a multi-layered material that
includes at least one layer that is resistant to tearing upon the
application of a peel force. Cover 18, or a tear resistant layer of
cover 18, preferably has a minimum tensile strength of 3000 psi and
a minimum elongation of 50%. Examples of materials that are
resistant to tearing include polyethylene (PE), polyethylene
terephthalate (PET) and polyamide PA6. A multi-layered material for
cover 18 may include at least one layer formed of a continuous film
of tear resistant material (laminated or extrusion coated) or a
non-continuous film such as a non-woven polymer, mesh or perforated
film. Examples of a multi-layered material for cover 18 include
(from outside layer to inside layer): PET/aluminum foil/PE,
PET/EVOH/PE, PET/metalized PET/PE or PET/PE. End wall 22 includes
at least one extraction region 32 adapted for being pierced by at
least one extraction needle 34 of a machine 36 for dispensing
product, such as a beverage, from the container 10 to a user's
cup.
[0041] Filter 14 is adapted to be disposed within body 12 to define
at least one ingredients chamber 46 in an upper region of the
interior space 24 for receiving one or more ingredients 16 and, for
filtering applications, at least one extraction chamber 48 exterior
to the ingredients chamber 46 in the interior space 24 for
receiving product, such as a beverage, from the at least one
ingredients chamber 46 prior to extraction using the extraction
needle 34.
[0042] "Filter" is defined herein to mean any material that is
suitable for defining a chamber for containing ingredients for a
desired purpose. Filter may perform a filtering or screening
function or may simply serve to separate ingredients from the
remainder of container.
[0043] "Ingredients" is defined herein to mean any material that is
desired for use within container for a desired purpose. Ingredients
may include food or beverage ingredients or other natural or
synthetic material (for example packaging preservatives) desired
for use within container.
[0044] In the case of a container 10 for preparing a beverage as
intended for the present embodiment, ingredients 16 may be coffee
grounds, tea leaves, chocolate powder, milk powder, instant coffee
or any other soluble or insoluble ingredients or combinations of
ingredients that may be used to prepare a beverage in a beverage
preparing machine 36 as described herein.
[0045] Filter 14 includes a gasket portion 50 that is adapted for
securing filter 14 to body 12 as described further below. Gasket
portion 50 includes a plurality of pores, openings or channels 62
(collectively referred to as channels 62 hereafter) suitable for
securing filter 14 between cover 18 and flange 28 as described
herein. Filter 14 also includes a filter portion 52 that is
disposed within interior space 24 to define ingredients chamber 46.
In a preferred embodiment, as described further below, filter
portion 52 is molded to a desired shape within interior space 24
once gasket portion 50 has been secured to body 12 and prior to
filling with ingredients 16.
[0046] Filter 14 may be formed of any material suitable for holding
and, where applicable, filtering the specific ingredients 16 that
are intended to be disposed within ingredients chamber 46.
[0047] Preferably, for beverage filtering applications, filter 14
is formed of a moldable non-woven filtration material that includes
a plurality of multi-component filaments that are bound or
interlocked by non-woven manufacturing techniques (such as spunbond
techniques) to form a web having channels 62 extending from one
side of filter 14 to the other. The basis weight for filter 14
adapted for filtering ingredients for preparing a single serving of
beverage is in the range of 8 to 400 grams per square meter (gsm),
preferably in the range of 40 to 150 gsm and more preferably in the
range of 60 to 120 gsm. More details of the preferred moldable
nonwoven filtration material for filter 14 are provided in
co-pending U.S. provisional patent application No. 61/723,644 and
regular U.S. patent application Ser. No. 14/074,024 which are
incorporated in their entirety herein by reference.
[0048] Gasket portion 50 of filter 14 is adapted to be secured by
way of a first bond 64 to the periphery of opening 16 of body 12
(and most preferably to the top surface of flange 28). First bond
64 may be formed by disposing a separate bonding material between
filter 14 and body 12 or it may be integrally formed from the
material of one or both of filter 14 and body 12 (as shown for
example in FIG. 5).
[0049] First bond 64 preferably comprises a peelable bond between
second surface 14b of filter 14 and first surface 12a of body 12
(top surface of flange 28) in order that filter 14 may be peeled
away from body 12.
[0050] "Peelable bond" is defined herein to mean a bond between two
materials that is sufficiently strong to allow both materials to
remain bonded together during normal conditions for manufacture,
shipment and use while being sufficiently weak to allow one
material to be peeled away from the other material by hand
following use.
[0051] First bond 64 is formed from a first bonding material 66
that is adapted for securing filter 14 to body 12. As noted above,
first bonding material 66 may be a separate material from filter 14
and body 12 or it may be an integral part of the material (either a
monolayer material or a layer of a multi-layered material) for one
or both of filter 14 and body 12.
[0052] One example of a preferred first bonding material 66 is a
heat sealable polymer such as polyethylene (PE) including low
density PE, linear low density PE and high density PE. This
material may be provided as a sealing layer for a multi-layered
material for body 12 or it may be provided as a separate first
bonding material 66.
[0053] Other suitable first bonding materials 66 include other heat
sealable materials such as polypropylene, lacquer, ethylene vinyl
acetate (EVA), ethylene acrylates, polystyrene or combinations of
the above. Adhesive materials (having comparable adhesion
properties as described above to form a peelable bond) may be
utilized for applications where a heat sealer is not desired or
feasible.
[0054] Suitable first bonding materials that may be integral with
filter 14 include homocomponent materials (such as polyolefin,
polyester, and polyamide) and multicomponent materials (such as
polyester-polyolefin, polyamide-polyolefin and
polyester-polyamide).
[0055] Cover 18 is adapted to be secured by way of a second bond 68
to gasket portion 50 of filter 14. In the embodiments depicted in
FIGS. 1-6, second bond 68 preferably is at least as strong and more
preferably is stronger than first bond 64 in order that filter 14
will remain secured to cover 18 when cover 18 is peeled from body
12.
[0056] Second bond 68 is preferably formed from a second bonding
material 70 that is adapted for securing a first surface 18a of
cover 18 to second surface 14b of filter 14. One example of a
preferred second bonding material is a heat sealable polymer such
as polyolefin. Other suitable second bonding materials 70 may
include other heat sealable materials such as lacquer, ethylene
vinyl acetate (EVA), and ethylene acrylates or adhesive materials
for applications where a heat sealer is not desired or
feasible.
[0057] The selection of the first bonding material 66 and second
bonding material 70 are interdependent and also depend on the
selection of other components within container 10 including filter
14. The strength or weakness of the bonds is related to the
compatibility of the respective materials being bonded together.
Less compatible bonds are adapted to separate prior to more
compatible bonds. More details concerning the preferred choice of
bonding materials are provided below with reference to FIGS.
6(a)-(d).
[0058] For the embodiments depicted in FIGS. 1-6, the bond strength
of second bond 68 is preferably at least as strong as the first
bond 64 and more preferably 50% higher than that of first bond 64
and even more preferably 100% higher or more. For example, using
the ASTM F88 protocol, the bond strength of first bond 64 is
preferably no more than 20 N/15 mm and more preferably no more than
10 N/15 mm. The bond strength of second bond 68 is preferably no
less than 15 N/15 mm and more preferably no less than 25 N/15
mm.
[0059] First and second bonding materials 66, 70 are preferably
adapted to become at least partially embedded within channels 62 of
gasket portion 50 of filter 14. Heat sealable polymers for example
will flow into channels 62 when melted during a heat sealing
process and then form a bond within channels 62 upon cooling. In
the case of filter 14 being formed of filtration material having
multi-component fibers, one or more portions of the multi-component
fibers may melt during the heat sealing process and combine with
the first or second bonding materials while other portions of the
multi-component fibers remain intact (do not melt) during the heat
sealing process to maintain a web defining channels 62. Preferably,
second bonding material 70 is chemically compatible in order that
it may be sealed to all the components of filter material 14 to
give a sufficiently strong seal strength. More details of filter 14
and the manner for securing filter 14 and cover 18 to flange 28 of
body 12 are provided in co-pending patent application Ser. No.
13/600,582 which is incorporated in its entirety herein by
reference.
[0060] Referring to FIG. 5, an exploded sectional view of a
container 10 in accordance with another embodiment of the present
invention is shown. The same reference numerals are provided for
elements that are similar to the elements described above.
[0061] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. While the body 12 and cover 18 of container 10 shown in
FIGS. 1-4 could be formed of a monolayered material, body 12 and
cover 18 for the embodiment shown in FIG. 5 are each formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0062] Body 12 is formed of a conventional multilayered material
MM1 that includes a barrier layer B1 preferably formed of ethylene
vinyl alcohol (EVOH) and a sealing layer S1 preferably formed of
polyethylene (PE). As well, body 12 may include outer base layer O1
preferably formed of polyolefin or polystyrene or other materials
adapted to cover and protect barrier layer B1.
[0063] Cover 18 is formed of a conventional multilayered material
MM2 that includes a barrier layer B2 preferably formed of aluminum
foil or metalized polyester or Ethylene Vinyl Alcohol (EVOH) and a
sealing layer S2 preferably formed of polyethylene or modified
polyethylene or polyethylene copolymer. Sealing layer S2 may be
formed from a lamination process, extrusion coating or lacquer
coating process. As well, cover 18 may include an outer base layer
O2 preferably formed of polyester and a graphics layer G2
preferably formed of ink. Depending upon the type of packing
machinery, cover 18 could be provided as roll stock or in die-cut
format.
[0064] It is preferred that cover 18 is formed of multilayered
material MM2 (such as described above) that is resistant to tearing
as described above and that shrinks when exposed to heat. This
allows cover to be peeled away from body 12 and also reduces the
likelihood of cover 18 being torn during the process of puncturing
with injection nozzle and injecting fluid into ingredients chamber
46. Multilayered material MM2 of cover 18 will also preferably
shrink around the opening formed by injection nozzle when exposed
to injection of hot fluid to reduce the size of opening. These
characteristics can be achieved by choosing a proper outer base
layer O2 such as polyester for providing rigidity to the cover
18.
[0065] Filter 14 is formed by disposing filtration material over
opening 26 of body 12. Gasket portion 50 of filter 14 engages
sealing layer S1 disposed on the top surface of flange 28 and
filter portion 52 extends across opening 26. Gasket portion 50 is
then sealed with a heat sealer to sealing layer S1 disposed on the
top surface of flange 28. A portion of sealing layer S1 on top
surface of flange 28 (also referred to herein as first bonding
material 66) is melted by heat sealer and flows into channels 62
within gasket portion 50. The gasket portion 50 of filter 14 may be
partially melted during this process if it contains multiple
component fibres while other portions of the multi-component fibers
remain intact (do not melt) during the heat sealing process to
maintain a web defining channels 62.
[0066] In addition to choosing desired first and second bonding
materials 66, 70, the temperature, pressure and time parameters for
the heat sealing process are optimized to ensure the desired
bonding strength is achieved for both first bond 64 and second bond
68. For example, with respect to both first bond 64 and second bond
68, the sealing temperature is preferably in the range of 100-250 C
and more preferably in the range of 160-220 C. The sealing pressure
is preferably in the range of 0.5-4 bar and more preferably in the
range of 1-3 bar. The sealing time is preferably in the range of
50-5000 milliseconds and more preferably in the range of 500-3000
milliseconds.
[0067] Once the melted first bonding material 66 sufficiently cools
to form first bond 64 to secure gasket portion 50 to flange 28,
then filter 14 may be molded for instance by engaging filter
portion 52 using a heated mandrel to mold filter portion 52 to a
desired shape within interior space of body 12 to form the
ingredients chamber 46. Then ingredients 16 are disposed within
ingredients chamber 46 of filter 14 and cover 18 is positioned over
gasket portion 50 to cover opening 26.
[0068] Cover 18 may then be partially sealed to gasket portion 50
using a heat sealer. A portion of the sealing layer S2 (also
referred to herein as second bonding material 70) on bottom surface
of cover 18 is melted by a heat sealer and flows into channels 62
of gasket portion 50. The air within interior space 16 of container
10 may then be evacuated and replaced with an inert gas such as
nitrogen in accordance with a modified atmosphere packaging
process. The remainder of cover 18 may then be fully sealed to body
12 over gasket portion 50 as described above to form second bond 68
and seal interior space 16 of container 10.
[0069] Body 12 preferably includes a notch 72 cut into at least
sealing layer S1 (first bonding layer 66) below the periphery of
opening 16. Notch 72 may, in certain applications where barrier
properties are not excessively compromised, also extend into
barrier layer B1 if necessary to provide a sufficient area weakness
as discussed below. Notch 72 provides an area of weakness for
ingredients chamber and first bonding material 66 (in this instance
sealing layer S1 at gasket 50) to be separated from body 12 when
tab 30 is pulled to peel cover 18 from body 12 following use of
container 10.
[0070] Adhesion or tie layers T may be disposed in known manner
between the respective layers B1, S1, O1 and G1 as described above
to adhere or tie the respective layers together. Adhesion or tie
layers T in body 12 may provide a relatively weak connection
between adjoining surfaces to allow for separating layers when
peeling cover 18 and ingredients chamber 46 from body 12.
[0071] Referring to FIGS. 6 (a)-(d), a number of examples of a
peelable bond between filter 14 and body 12 are shown.
[0072] FIGS. 6(a) and 6(b) show first bond 64 being formed using a
separate material (first bonding material 66) disposed between
first surface 14a of filter 14 and first surface 12a of body
12.
[0073] In FIG. 6(a) the peel strength of the first bond 64 between
first surface 14a of filter 14 and first bonding material 66 is
greater than the peel strength of the first bond 64 between first
bonding material 66 and first surface 12a of body 12. As a result,
filter 14 and first bonding material 66 are peeled away from first
surface 12a of body 12 upon the application of a sufficient peeling
force to filter 14.
[0074] The choice of materials for the example shown in FIG. 6(a)
include the following. Filter 14 may be formed of .gtoreq.20% LDPE
or LLDPE and cover 18 may be formed of PE, EVA, EAA or a
combination of two or more of these materials. In this case, first
bonding material 66 and second bonding material 70 may be formed
from LDPE, EVA (Dupont Bynel.TM.) or modified PE (Dow
Sealution.TM.). It will be understood that other choices of
materials may selected as well.
[0075] In FIG. 6(b) the peel strength of the first bond 64 between
first surface 14a of filter 14 and first bonding material 66 is
less than the peel strength of the first bond 64 between first
bonding material 66 and first surface 12a of body 12. As a result,
filter 14 is peeled away from first bonding material 66 upon the
application of a sufficient peeling force to filter 14.
[0076] The choice of materials for the example shown in FIG. 6(b)
include the following. Filter 14 may be formed of .ltoreq.20% LDPE
or LLDPE, PP, PA or Polyester and cover 18 may be formed of a PE,
EVA, EAA or a combination of two or more of these materials. In
this case, first bonding material 66 may be formed from LDPE, EVA
(Dupont Bynel.TM.) or modified PE (Dow Sealution.TM.). Second
bonding material 70 may be formed from polyester or other suitable
materials provided that the second bond 68 is stronger than first
bond 64. It will be understood that other choices of materials may
selected as well.
[0077] FIGS. 6(c) and 6(d) show first bond 64 being integrally
formed from a layer of a multilayered material MM1 forming body
12.
[0078] In FIG. 6(c) the peel strength of the first bond 64 between
first surface 14a of filter 14 and first bonding material 66 (which
is the sealing layer S1 of the multilayered material MM1 forming
body 12) is greater than the peel strength of the first bond 64
between first bonding material 66 and the adjacent layer of the
multilayered material MM1. The adjacent layer may be a tie layer
formed of a low compatibility material such as Surlyn.TM. or
Bynel.TM. or adjacent layer may be barrier layer B1. As a result,
filter 14 and first bonding material 66 (ie a portion of the
sealing layer S1 of multilayered material MM1) are peeled away upon
the application of a sufficient peeling force to filter 14. This
example is described in more detail above with reference to FIG. 5.
Notch 72 defines a break point to allow a portion of sealing layer
S1 to be removed with filter 14 while the remainder of sealing
layer S1 stays within body 12.
[0079] The choice of materials for the example shown in FIG. 6(c)
include the following. Filter 14 may be formed of .gtoreq.20% LDPE
or LLDPE, PP, PA or Polyester and cover 18 may be formed from PE,
EVA, EAA or a combination of two or more of these materials. In
this case, first bonding material 66 may be formed from LDPE,
LLDPE, HDPE, EVA or a combination of two or more of these
materials. Second bonding material 70 may be formed from PE, EVA,
EAA or a combination of two or more of these materials. It will be
understood that other choices of materials may selected as
well.
[0080] In FIG. 6(d) the peel strength of the first bond 64 between
first surface 14a of filter 14 and first bonding material 66 is
less than the peel strength of the first bond 64 between first
bonding material 66 and the adjacent layer of the multilayered
material MM1. As a result, filter 14 is peeled away from first
bonding material 66 (ie away from first surface 12a of body 12 or,
in other words, away from sealing layer S1 of multilayered material
MM1 that forms body 12) upon the application of a sufficient
peeling force to filter 14.
[0081] The choice of materials for the example shown in FIG. 6(d)
include the following. Filter 14 may be formed of .gtoreq.20% LDPE
or LLDPE and cover 18 may be formed of PE, EVA, EAA or a
combination of two or more of these materials. In this case, first
bonding material 66 (sealing layer S1) may be formed from HDPE, PP
or PS. Second bonding material 70 may be formed from PE, EVA, EAA
or a combination of two or more of these materials. It will be
understood that other choices of materials may selected as
well.
[0082] Referring to FIG. 7, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0083] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. If desired, body 12 and cover 18 may each be formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0084] In this embodiment, second bond 68 between filter 14 and
cover 18 comprises a peelable bond similar to first bond 64 as
described for the embodiments above. For example, the peel strength
of the second bond 68 between second surface 14b of filter 14 and
second bonding material 70 may be less than the peel strength of
the second bond 68 between second bonding material 70 and the first
surface 18a of cover 18. As a result, filter 14 may be peeled away
from second bonding material 70 (ie away from first surface 18a of
body 12) upon the application of a sufficient peeling force to
filter 14.
[0085] Filter 14 and cover 18 also preferably each include tabs 30a
and 30b that are preferably aligned to provide a common grip for
peeling filter 14, ingredients 16 and cover 18 from body 12. Tabs
30a and 30b may then be separately gripped to peel cover 18 away
from filter 14 and ingredients 16. This allows the user to dispose
of body 12, filter 14, ingredients 16 and cover 18 in one of
multiple desired locations.
[0086] The choice of materials for the example shown in FIG. 7
include the following. Filter 14 may be formed of .gtoreq.20% LDPE
or LLDPE and cover 18 may be formed of HDPE, PP or PS. In this
case, first bonding material 66 (sealing layer S1) and second
bonding material 70 (sealing layer S2) may be formed from HDPE, PP
or PS. Alternatively, filter 14 may be formed of .ltoreq.20% LDPE
or LLDPE, PP, PA or Polyester and cover 18 may be formed from LDPE,
LLDPE, HDPE, EVA or a combination of these materials. In this case,
first bonding material 66 (sealing layer S1) and second bonding
material 70 (sealing layer S2) may be formed from LDPE, LLDPE,
HDPE, EVA or a combination of these materials. It will be
understood that other choices of materials may selected as
well.
[0087] Referring to FIG. 8, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0088] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. If desired, body 12 and cover 18 may each be formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0089] In this embodiment, filter 14 is secured to sidewall 20 of
body 12 by way of first bond 64 using first bonding material 66.
First bond 64 is a peelable bond as described above. Filter 14
includes tab 30a that provides a grip for peeling filter 14 from
body 12. Tab 30a is preferably folded away from flange 28.
[0090] Cover 18 is secured to flange 28 of body 12 by way of second
bond 68 using second bonding material 70. Second bond 68 is also a
peelable bond as described above. Cover 18 includes tab 30b that
provides a grip for peeling cover 18 from body 12.
[0091] As a result, once container 10 has been used for its
intended purpose, a user will grip tab 30b to peel cover away from
body 12. The user will then grip tab 30a to peel filter 14 together
with ingredients 16 away from body 12. This allows the user to
dispose of body 12, filter 14, ingredients 16 and cover 18 in one
of multiple desired locations.
[0092] The choice of materials for the example shown in FIG. 8
include the following. Filter 14 may be formed of .gtoreq.20% LDPE
or LLDPE and cover 18 may be formed of LDPE, LLDPE, HDPE, EVA,
modified PE or a combination of these materials. In this case,
first bonding material 66 (sealing layer S1) and second bonding
material 70 (sealing layer S2) may be formed from HDPE, PP or PS.
Alternatively, filter 14 may be formed of .ltoreq.20% LDPE or
LLDPE, PP, PA or Polyester and cover 18 may be formed from LDPE,
LLDPE, HDPE, EVA or a combination of these materials. In this case,
first bonding material 66 (sealing layer S1) and second bonding
material 70 (sealing layer S2) may be formed from LDPE, LLDPE,
HDPE, EVA or a combination of these materials. It will be
understood that other choices of materials may selected as
well.
[0093] Referring to FIGS. 9-11, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0094] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. If desired, body 12 and cover 18 may each be formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0095] Instead of having a separation of cover 18 and ingredients
chamber 46 from body 12, this embodiment provides a separation of
one portion of body 12, such as flange 28, from the rest of body
12. Cover 18 with filter 14 defining ingredients chamber 46
containing ingredients 16 remains connected to the removed portion
of body 12, such as flange 28, following such separation.
[0096] Continuing with the example where flange 28 is being removed
from the remainder of body 12, a separation point 80 is defined in
body 12 preferably proximate to the interface between flange 28 and
side wall 20. Separation point 80 may be a score line (a continuous
indentation) or perforation line (a line of discrete indentations)
that is adapted to break or separate upon the application of force.
Separation point 80 may be defined in body 12 either during or
following the process for forming body 12 for instance by
thermoforming. The separation point 80 may be defined only in the
outer surface (second surface 12b) of body 12 or it may be defined
in both the outer surface and inner surfaces (second surface 12b
and first surface 12a) of body 12. Preferably, separation point 80
is formed through an in-mold cutting process during thermoforming
of body 12 or at a separate station following formation of body
12.
[0097] In one variant as shown in FIG. 10, separation point 80 may
extend about circumference of body 12 and be adapted to separate
upon application of opposing twisting forces to flange 28 and side
wall 20 (as shown in FIG. 6) similar to twisting a cap from a
bottle. Separation point 80 is shown defined in flange 28 adjacent
to the interface with side wall 20. It will be understood that
separation point 80 could alternatively be defined in side wall 20
proximate to interface with flange 28. Filter 14 may be bonded to
side wall 20 between separation point 22 and flange 28. Filter 14
is preferably formed of a non-woven material as described above but
may alternatively be formed from a conventional paper filter
material if desired since it is not subjected to significant tear
forces.
[0098] In another variant as shown in FIG. 11, separation point 80
may be defined in flange 28 about circumference of body 12 and
include a portion extending to peripheral wall of flange 28 to
define tab 30 for peeling flange 28 with cover 18 and filter 14
with ingredients chamber 46 from the remainder of body 12.
[0099] Referring to FIGS. 12-13, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0100] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. If desired, body 12 and cover 18 may each be formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0101] In this embodiment, cover 18 is bonded with second bonding
material 68 to the first surface 12a of body 12 (top surface of
flange 28) in the same manner as described for the embodiments
shown in FIGS. 1-6.
[0102] A separation point 80 is defined along at least one portion
of body 12, such as flange 28, to form at least one tab 30 (and
preferably two tabs 30 as shown). Separation point 80 may be formed
for example by a score line or perforation line that is adapted to
break or separate from flange 28 upon the application of sufficient
force. The force for instance may be applied by upward pressure,
for instance by a person's thumb, along the bottom side of tab 30
until tab 30 snaps and separates from flange 28.
[0103] Separation point 80 is preferably made through scoring or
perforating during the same operation that is utilized for
thermoforming body 12 or at a subsequent station. Separation point
80 may be defined along the second surface 12b of body 12 (bottom
surface of flange 28) without significantly disrupting or
negatively impacting the ability of cover 18 to be peelably sealed
to the top surface of flange 28 such as described for the
embodiments shown in FIGS. 1-6. Separation point 80 may for
instance extend a desired distance into the bottom surface of
flange 28 without breaking the top surface. Preferably, separation
point 80 is defined in both the outer surface and inner surfaces
(second surface 12b and first surface 12a) of body 12. Preferably,
for containers 10 formed of multilayered materials MM, separation
point 80 does not break or significantly disrupt the barrier layer
B.
[0104] Preferably, a tab indicator 82 is disposed on body 12 to
indicate the location of tab 30. Tab indicator may be embossed onto
the outer surface of sidewall 20 of body 12 in the same operation
utilized for thermoforming body 12. Tab indicator 82 may
alternatively be printed or adhered onto the material for forming
body 12 at locations that align with the molds 84 that are adapted
for formation of body 12 and separation point 80 as shown in FIG.
14.
[0105] Following use of container 10, allowing sufficient time for
the container 10 to cool if necessary, a user will apply force to
tab 30 along the bottom portion of tab 30 until the tab 30 snaps
free from the remainder of flange 28 along separation point 80. The
user may hear a snap sound to indicate that tab 30 has separated
from flange 28. The user then applies a peeling force to tab 30 in
order to peel cover 18 and filter 14 with ingredients chamber
containing ingredients 16 from body 12. Body 12 may be disposed
into plastics recycling and cover 18 and filter 14 with ingredients
chamber and ingredients 16 may be disposed into garbage destined
for landfill or further processed or separated for disposal or
recycling purposes.
[0106] As noted earlier, container 10 preferably is symmetrical
with an annular flange 28 having a uniform width W with separation
point 80 defining tab 30 within the uniform width W of flange 28.
This is preferable to having a portion of flange 28 with tab 30
extend beyond the uniform width W of the remainder of flange 28
which could complicate the manufacture and packaging of container
10 and which may prevent conta8iner from being utilized in a
machine 36.
[0107] Referring to FIGS. 15 and 16, a container 10 in accordance
with another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0108] Container 10 includes body 12, ingredients 16 and cover 18.
If desired, body 12 and cover 18 may each be formed of multilayered
materials that include one or more barrier layers providing
barriers against one or more environmental factors such as light,
oxygen, and moisture as described further below.
[0109] This embodiment of container 10 is similar to the embodiment
shown in FIGS. 12 and 13 but does not include filter 14. A tab 30
is defined in body 12 (preferably in flange 28) by separation point
80. Cover 18 is bonded by second bond 68 to the portion of body 12
(preferably to flange 28) that includes tab 30 defined by
separation point 80. Second bond 68 is a peelable bond as described
above to allow cover 18 to be peeled away with tab 30 from the
remainder of body 12. Tab indicator 82 is provided, as described
above, to assist the user in locating tab 30.
[0110] This embodiment may be applied to a wide variety of
containers 10. The separation point 80 defining tab 30 may be
integrally formed within the body 12 of container 10 without adding
significant costs or adding significant complexity to the overall
structure of the container.
[0111] Referring to FIG. 17, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0112] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. In this embodiment, body 12 comprises flange 28 and a
partial side wall 20 adapted to support filter 14. Body 12 does not
include a full side wall 20 and end wall 22 for defining a fully
enclosed interior space.
[0113] In all other respects, container 10 is similar to the
embodiments described above with a portion of container 10 being
removable from the remainder of container 10. For example, filter
14 may be bonded to body 12 (either to flange 28 or side wall 20)
with a first bond 64 that is a peelable bond. Cover 18 may be
bonded to filter 14 or to body 12 (such as to flange 28) with a
second bond that may also be a peelable bond if desired.
[0114] Referring to FIG. 18, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0115] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. If desired, body 12 and cover 18 may each be formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0116] In this embodiment, body 12 further comprises a shoulder 90
disposed inwardly from flange 28 to support filter 14. Filter 14
may be bonded to a support ring 92 that is adapted to either rest
loosely upon shoulder 90 as shown or be bonded to shoulder with a
first bond 64 that is preferably a peelable bond (not shown). Cover
18 is bonded to flange 28 with second bond 68 that is a peelable
bond as described for the embodiments above.
[0117] This embodiment of container allows filter 14 to be disposed
within container 10 without bonding to the same flange surface as
cover 18. Upon peeling away cover 18 following the use of container
10, filter 14 and ingredients 16 may be removed from container
either by tipping container upside down (if ring rests loosely upon
shoulder 90) or by peeling away ring and filter 14 preferably with
the aid of a tab (not shown).
[0118] Referring to FIG. 19, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0119] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. If desired, body 12 and cover 18 may each be formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0120] In this embodiment, container 10 is similar to the container
shown in FIG. 18. Shoulder 90 includes a slot 94 that is adapted to
receive a portion of filter 14 and support ring 92. Support ring 92
is preferably configured to support filter 14 within slot 94 by way
of a friction fit.
[0121] This embodiment of container also allows filter 14 to be
disposed within container 10 without bonding to the same flange
surface as cover 18. Upon peeling away cover 18 following the use
of container 10, filter 14 and ingredients 16 may be removed from
container by peeling away ring and filter 14 preferably with the
aid of a tab 30.
[0122] Referring to FIG. 20, a container 10 in accordance with
another embodiment of the present invention is shown. The same
reference numerals are provided for elements that are similar to
the elements described above.
[0123] Container 10 includes body 12, filter 14, ingredients 16 and
cover 18. If desired, body 12 and cover 18 may each be formed of
multilayered materials that include one or more barrier layers
providing barriers against one or more environmental factors such
as light, oxygen, and moisture as described further below.
[0124] In this embodiment, container 10 is similar to the container
shown in FIG. 19 however no shoulder 90 is provided. Instead, slot
94 is defined in flange 28. Slot 94 is adapted to receive a portion
of filter 14 and support ring 92.
[0125] Cover 18 is bonded to support ring 92 as well as to flange
28 by a peelable bond. Upon peeling away cover 18 following the use
of container 10, filter 14 and ingredients 16 may be removed from
container.
[0126] While the above description provides examples of one or more
processes or apparatuses, it will be appreciated that other
processes or apparatuses may be within the scope of the
accompanying claims.
* * * * *