U.S. patent application number 14/146909 was filed with the patent office on 2014-07-31 for method and apparatus for packaging and dispensing goods.
The applicant listed for this patent is Mark L. Ballering. Invention is credited to Mark L. Ballering.
Application Number | 20140208691 14/146909 |
Document ID | / |
Family ID | 51221418 |
Filed Date | 2014-07-31 |
United States Patent
Application |
20140208691 |
Kind Code |
A1 |
Ballering; Mark L. |
July 31, 2014 |
METHOD AND APPARATUS FOR PACKAGING AND DISPENSING GOODS
Abstract
An packaging apparatus is disclosed that comprises, a tray
having a top surface, a bottom surface, and a sidewall, one or more
compartments integrally formed with and extending from the tray,
and one or more pods for housing a product, the pods further
comprising, a pouch with a cover secured to the pouch to provide
closure of the pod, the cover including a bottom cover surface and
a top cover surface, and a tab layer secured at least partially to
the top cover surface, wherein the pods are received and at least
partially enclosed by the compartments, and the pods are secured to
the tray.
Inventors: |
Ballering; Mark L.;
(Madison, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ballering; Mark L. |
Madison |
WI |
US |
|
|
Family ID: |
51221418 |
Appl. No.: |
14/146909 |
Filed: |
January 3, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61757842 |
Jan 29, 2013 |
|
|
|
Current U.S.
Class: |
53/432 ;
220/23.83; 220/359.2; 53/449 |
Current CPC
Class: |
B65D 2577/2058 20130101;
B65D 77/2024 20130101; B65D 85/8043 20130101; B65D 77/048
20130101 |
Class at
Publication: |
53/432 ;
220/359.2; 220/23.83; 53/449 |
International
Class: |
B65D 77/30 20060101
B65D077/30; B65D 85/804 20060101 B65D085/804 |
Claims
1. A pod apparatus comprising: a pouch for housing a product; a
cover secured to the pouch to provide closure; and a tab layer
secured at least partially to the cover to provide a graspable
portion.
2. The apparatus of claim 1, wherein the cover is formed of a rigid
material and the tab layer is formed of a flexible material.
3. The apparatus of claim 1, wherein only a portion of the tab
layer is removable from the cover.
4. An apparatus comprising: a tray having a top surface, a bottom
surface, and a sidewall; one or more compartments integrally formed
with and extending from the bottom surface of the tray; one or more
pods for housing a product, the pods further comprising: a pouch; a
cover secured to the pouch to provide closure of the pod, the cover
including a bottom cover surface and a top cover surface; and a tab
layer secured at least partially to the top cover surface, wherein
the pods are received and at least partially enclosed by the
compartments, and the pods are secured to the tray.
5. The apparatus of claim 4, wherein the cover bottom surface is
secured to the top surface of the tray.
6. The apparatus of claim 4, wherein the tab layer includes a tab
portion.
7. The apparatus of claim 6, wherein the one or more pods are
separable from the tray by exerting a pulling force on the tab
portion.
8. The apparatus of claim 7, wherein separation of the one or pods
using the tab portion does not separate the cover from the
pouch.
9. A method of packaging goods comprising: filling a pouch with a
product; securing the pouch to a cover to enclose the product,
wherein the cover includes a tab layer secured thereto; providing a
substrate material having a top surface and one or more
compartments extending therefrom; positioning the pouch inside a
compartment of a tray, wherein the tray includes a top surface; and
securing the cover to the tray top surface.
10. The method of claim 9, further comprising injecting a gas
inside the compartment to substantially displace oxygen in the
compartment.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present Application is a non-provisional application and
claims the benefit of U.S. provisional patent application No.
61/757,842 having the same title as the present Application and
filed on Jan. 29, 2013, of which the present Application hereby
incorporates by reference in its entirety.
FIELD
[0002] The method and apparatus relate to the packaging and
dispensing of goods.
BACKGROUND
[0003] Products can be packaged together in numerous ways to
provide advantages with storage, transport, dispensing, and cost.
Commonly, products such as food can be combined in large quantities
in a container to save on the cost of extra packaging materials.
Alternatively, a small quantity of products can be packaged
together to maintain separation and/or freshness. For example,
coffee creamer can be purchased in a large 1-liter bottle or in a
box of 192 individually packaged 13-milliliter units. Although
these individual units provide a solution for maintaining
freshness, they require extensive packaging materials and are
positioned loosely about the box, making accounting difficult as
the units are consumed, and creating organizational storage
problems if they are removed from the box.
BRIEF SUMMARY
[0004] In at least some embodiments, the method and apparatus
relate to a packaging tray apparatus that includes a substantially
planar substrate having a top surface, a bottom surface, a
sidewall, and one or more compartments integrally formed with and
extending from the substrate.
[0005] Further, in at least some embodiments, the method and
apparatus relate to a pod apparatus that includes a pouch for
housing a product, a cover secured to the pouch to provide closure,
and a tab layer secured at least partially to the cover to provide
a graspable portion.
[0006] Additionally, in at least some embodiments, the method and
apparatus relate to an apparatus that includes a substrate material
having a top surface, a bottom surface, and a sidewall; one or more
compartments integrally formed with and extending from the
substrate; one or more pods for housing a product, the pods further
comprising a pouch, a cover secured to the pouch to provide
closure, the cover including a bottom cover surface and a top cover
surface, and a tab layer secured at least partially to the top
cover surface, wherein the pods are received and at least partially
enclosed by the compartments, and the pods are secured to the
substrate.
[0007] In addition, in at least some embodiments, the method and
apparatus relate to a method of packaging goods that includes
filling a pouch with a product; securing the pouch to a cover to
enclose the product, wherein the cover includes a tab layer secured
thereto; providing a substrate material having a top surface and
one or more compartments extending therefrom; positioning the pouch
inside a compartment of a tray, wherein the tray includes a top
surface; and securing the cover to the tray top surface.
[0008] Other embodiments, aspects, features, objectives, and
advantages of the method and apparatus will be understood and
appreciated upon a full reading of the detailed description and the
claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Embodiments of the method and apparatus are disclosed with
reference to the accompanying drawings and are for illustrative
purposes only. The method and apparatus are not limited in their
application to the details of construction or the arrangement of
the components illustrated in the drawings. The method and
apparatus are capable of other embodiments or of being practiced or
carried out in other various ways. In the drawings:
[0010] FIG. 1 is a top view of an exemplary packaging and
dispensing apparatus that includes a packaging tray and a pod;
[0011] FIG. 2 is a side view of the packaging and dispensing
apparatus of FIG. 1;
[0012] FIG. 3 is a cross-sectional view of an exemplary pod;
and
[0013] FIG. 4 is an enlarged cross-sectional view of the pod of
FIG. 2 and a portion of the packing tray of FIG. 2.
DETAILED DESCRIPTION
[0014] Referring to FIGS. 1 and 2, an exemplary packaging and
dispensing apparatus 100 is illustrated. The packaging and
dispensing apparatus 100 includes an exemplary packaging tray 102
that is configured to secure and dispense one or more pods 104 that
individually contain one or more products 106. The packaging and
dispensing apparatus 100 provides a convenient and efficient method
of packaging products 106 that provides for bulk shipping and
storage, while allowing for individual dispersion of pre-determined
amounts of product 106.
[0015] The exemplary packaging tray 102 and pods 104 can include
numerous embodiments. Referring particularly to FIG. 1, the tray
102 includes a substrate 108 having a tray top surface 110, a tray
bottom surface 112, and a tray sidewall 114. The substrate 108 can,
in at least some embodiments, be comprised of numerous materials,
such as paper, laminates, plastic, metal, and any combination
thereof (e.g., plastic film coated with a metalized layer).
Further, in at least some embodiments, the substrate 108 can be
substantially planar and include a semi-rigid tray sidewall 114
having a thickness of about 3 mm to about 10 mm, and an oxygen
transmission rate (OTR) in the range of about 0.00 cc/100 sq. in.
to about 0.05 cc/100 sq. in. In addition, the substrate 108 can
have a length L of about 10 cm to about 150 cm and a width W1 of
about 5 cm to about 50 cm. In other embodiments, the substrate 108
can have various other thicknesses, lengths, widths, rigidity
levels, and gas permeability levels. The tray 102 can further
include a product label 130 (e.g., indicia) for identification of
the product 106, UPC code, etc. In addition, the tray 102 can
include an aperture 132 for providing a hanging position on a rack.
Further, the substrate 108 can include scoring between the openings
116 to allow for separation of the pods 104 while intact in the
tray 102.
[0016] One or more openings 116 are provided in the substrate 108,
with each opening 116 including a rim portion 118 located on the
substrate 108 that extends adjacent to and around the opening 116.
One or more compartments 120 are integrally formed with the
substrate 108 at the openings 116 and extend downward from the
substrate 108. The compartment 120 is configured to receive the
pods 104 and provide a sealable, protective, recessed storage
position. The quantity of compartments 120 formed in the tray 102
can vary. In at least some embodiments from 1 to about 12
compartments can be provided, while in other embodiments 1 to about
48 compartments can be provided, while in still other embodiments,
more than 48 compartments can be provided. The compartments 120
include a compartment sidewall 122 that extends from the tray
bottom surface 112 to a compartment bottom surface 124. The
compartments 120 can include various shapes and sizes to
accommodate various types of products 106, for example,
cylindrical, conical, rectangular, convex, etc. Further, in at
least some embodiments, the substrate 108 includes a plurality of
perforations 126 to facilitate separation of the substrate for
removal of individual pods 104 from the tray 102.
[0017] In at least some embodiments, as shown in FIG. 2, the
compartments 120 include a tapered-cylindrical shape, and extend a
height H (vertical distance between the tray bottom surface 112 and
the compartment bottom surface 124) of about 30 mm to about 40 mm.
Further, the width W2 of the opening 116 can extend from about 40
mm to 46 mm, and the width W3 of the compartment bottom surface 124
can extend from about 35 mm to about 41 mm. In another embodiment,
the height H extends from about 5 mm to about 100 mm and the widths
W2 and W3 extend from about 5 mm to about 25 cm. In other
embodiments, the height H and widths W2 and W3 include greater or
lesser distances. In at least some embodiments, the substrate 108
can include one or more access depressions 134 (FIGS. 1 and 2).
[0018] Referring to FIG. 3, an exemplary pod 104 is illustrated.
The pod 104 can be utilized to store one or more of various
products 106, such as consumables (i.e., food products), medical
supplies, chemicals, cosmetics, etc. The pod 104 includes a pouch
140 having an upper portion 142, a lower portion 144, an inner
surface 146, and an outer surface 148. The pouch 140 can include
one or more of various materials suitable for housing products 106.
The pouch 140 can vary in shape, size, and composition dependent on
the type of product 106 to be housed in the pouch 140. In at least
some embodiments, the pouch 140 can include one or more of various
materials suitable for filtering, for example, non-woven paper,
woven fiber meshing, and synthetic meshing. In other embodiments,
the pouch 140 can be comprised of a waterproof material, such as
plastic, to accommodate liquid products 106.
[0019] The pod 104 further includes a cover 150 that is secured to
the pouch 140 to secure the product 106 inside the pod 104. The
cover 150 includes a cover bottom surface 154 and a cover top
surface 156. When the cover 150 is secured to the pouch 140, the
cover bottom surface 154 and the inner surface 146 of the pouch 140
form a product chamber 172 for housing the product 106. The pouch
upper portion 142 is secured to the cover bottom surface 154.
Securement of the pouch 140 to the cover 150 can be accomplished in
various manners, such as through the use of an adhesive 152 (e.g.,
heat sealable paper, etc.). If the product 106 is a consumable,
then food grade adhesive can be used. In at least some embodiments,
the adhesive 152 can include or serve as a sealant 160. The cover
150 can be comprised of one or more of various materials, such as
paper, plastic, foam, plastic film, silicon rubber, metal foil on
paper, coated paper (wax, starch, or other coating layer that
prevents oxygen and/or water transfer), etc. In at least some
embodiments, the cover 150 has a thickness T ranging from about 1
mm to about 10 mm, although in other embodiments, the thickness T
can be less than 1 mm or greater than 10 mm. Further, in at least
some embodiments, the cover 150 is comprised of a material with a
low gas permeability, for example an OTR of less than 1.0, although
in other embodiments the OTR can be greater than or equal to
1.0.
[0020] In addition to sealing the pouch 140, the cover 150 also
provides for securement of the pod 104 to the tray top surface 110,
and thereby securing the pouch 140 inside the compartment 120.
Referring to FIG. 4, the pod 104 is illustrated in a securement
position with the tray 102. More particularly, the cover bottom
surface 154 is secured to the rim portion 118 of the substrate 108.
In at least some embodiments, this is accomplished using a sealant
160 that adheres and seals the cover bottom surface 154 to the rim
portion 118. The sealant 160 can include, for example, heat
sealable laminate that can be peeled off, non-permanent adhesive
tape, non-permanent glue, and pre-formed sealant rings. The cover
150 is sized and shaped to overlap the opening 116 and includes a
sealing portion 162 that is positionable over the rim portion 118
of the substrate 108. The cover 150 has a diameter D (FIG. 1) that
is sized and shaped to cover the opening 116 and extend over the
rim portion 118. In at least some embodiments, the diameter D is
about 5 mm to about 150 mm, although in other embodiments, the
diameter D can be less than 5 mm and greater than 150 mm. In
addition, the opening 116 and/or the cover 150 can be the same
shape or different shapes, including circular, square, etc. In at
least some embodiments, the substrate 108 includes perimeter
depressions 164 that allow for a flush or at least partially flush
mounting of the cover 150 relative to the tray top surface 110, as
shown in FIG. 4. In other embodiments, the substrate is flat or
substantially flat, as shown in FIG. 2.
[0021] In at least some embodiments, a tab layer 166 can be
provided integral with, or secured at least partially to, the cover
top surface 156. The tab layer 166 includes a tab portion 168 that
can be accessed and pulled to break the seal formed by the sealant
160 and remove the pod 104 from the tray 102. The tab layer 166 can
be comprised of one or more of various materials and can be sized
greater than, equal to, or smaller than the cover top surface 156.
The tab portion 168 is formed with the tab layer 166 and can be
temporarily secured to the cover top surface 156 with an adhesive
157 and forcibly released from the cover top surface 156 for
accessibility. The adhesive 157 can be a light-tack adhesive to
allow for easy lifting of tab portion 168 from the cover top
surface 156. The tab portion 168 can also be an extended portion of
the tab layer 166 that extends beyond the cover top surface 156 for
convenient accessibility. The tab layer 166 can be comprised of one
or more of various materials, such as paper, plastic film, metal
foil, etc. In at least some embodiments, the tab portion 168 can
also be used to remove the cover 150 from the pouch 140, when the
product 106 is not intended to remain in the pouch 140 during use.
Alternatively, the tab portion 168 can be used to remove the pod
104 from the tray 102 and the cover 150 can be secured to the pouch
140 with adhesive 152 that allows for practical removal of the
cover 150. In addition, in at least some embodiments, pulling on
the tab portion 168 provides removal of the pod 104 from the tray
102 without removing the cover 150 from the pod 104, thereby
leaving the product 106 sealed inside the pod 104 after removal
from the tray 102.
[0022] In at least some embodiments, the product 106 includes
ingredients for brewing coffee (i.e., processed coffee beans,
flavorings, etc.). When the pod 104 is intended for brewing coffee,
the pod 104 can be sized and shaped to be placed inside a coffee
brewer machine, such as coffee brewer machines manufactured by
Keurig Inc. (e.g., Keurig K-Cup compatible brewers). In such an
application, the cover 150 and tab layer 166 are configured to be
penetrable by a puncturing needle of a coffee brewer machine. In
contrast to various K-Cup style products used by various coffee
brewer machines, the pods 104 can be manufactured with a filter
pouch 140 instead of a plastic housing, wherein the filter pouch
140 is adhered to the cover 150 without the need for reinforcement
or the inclusion of plastic. As such, the pod 104 can be
manufactured using only paper-based materials, eliminating the need
for the use of plastic. The elimination of plastic allows for the
pod 104 to be biodegradable, and eliminates the need for recycling.
Likewise, the tray 102 can be manufactured using only paper-based
materials and also be biodegradable. Further, by securing the pods
104 directly to the tray top surface 110, the need for an overlay
or covering (plastic laminate, etc.) on the tray top surface 110 is
eliminated. In addition, the individual sealing and adhering allows
for a variety of pods 104 to be installed in the compartments, with
each compartment 120 having a suitable gas to accommodate the
product 106 therein. For example, coffee flavorings can require
nitrogen, while apple cider ingredients can require a different gas
injection. In addition, during manufacturing, the compartments 120
need not be filled in each tray 102 prior to sealing the pods 104
to the tray 102, thereby providing flexibility for at least the
addition of pods 104 with different products 106, such as a
multi-pack. Further, as the cover 150 can be semi-rigid or rigid,
the pod 104 is suitable for use in various coffee brewer machines
that require a substantially rigid top surface to accommodate a
puncturing needle. In contrast, a pod 104 having a soft
filter-based portion on top would not function in such coffee
brewers, instead requiring insertion into a beverage cup for the
addition of hot water.
[0023] As brewer machines often include the capability of brewing
beverages other than coffee, such as tea, cocoa, cider, etc., the
pouch 140 can include, as the product 106, the necessary
ingredients for other beverages (e.g., tea leaves, dehydrated apple
cider, etc.). In addition, by packaging the pod 104 within the tray
102, the pod 104 requires less material to support or protect the
product 106, thereby reducing both the cost of each pod 104 and the
effect on the environment. Additionally, as the size of the pouches
140 and compartments 120 can vary, the amount of product 106 can be
varied to provide a greater or lesser quantity of product 106 in
each pod 104. Further, the quantity of product 106 can be varied in
each pod 104 without changing the overall dimensions. For example,
in at least some embodiments, if the product 106 includes coffee
grinds, the amount of product 106 can range from about 10 grams to
about 60 grams, to provide a consumer with a greater range of
choices for strength of the coffee brewed from the pod 104.
[0024] To provide and/or maintain a suitable environment for
various types of products 106, the compartment 120 can be injected
with a gas 170 (FIG. 4), such as nitrogen, that displaces the
oxygen to reduce oxidation or other sources of degradation of the
product 106 over time. The gas 170 is sealed in the compartment 120
by the cover 150, which is sealed to the tray top surface 110 with
the sealant 160. This seal is maintained until a consumer lifts the
pod 104 out of the tray 102 by pulling the tab portion 168 and
detaching portions of the sealant 160. As the packaging and
dispensing apparatus 100 provides a sealed product 106, no
additional overwrap or display enclosure is required. The packaging
and dispensing apparatus 100 can include all necessary and/or
desired graphics, such as displayed on the tray top surface 110
and/or tab layer 166. The packaging and dispensing apparatus 100
can be configured to include depressions or protrusions that
enhance stackability, both when the pods 104 are in the tray 102
and after the pods 104 have been removed.
[0025] In addition to food-based products, various non-consumables,
such as medical supplies, medicines, etc., can be stored in the
pods 104. Use of the pods 104 in combination with the tray 102
allow for products 106 to be contained in a sterile environment
until needed, while allowing them to be manufactured, shipped,
and/or stored in an efficient manner. For example, if the product
106 was a medical instrument, such as a scalpel or clamp, the
packaging and dispensing apparatus 100 can be placed in a surgical
suite to provide a surgeon access to a selection of medical
instruments, without the need to expose unused medical instruments
to the environment. Likewise, a portioned amount of a disinfectant,
such as iodine and alcohol, can be located in the pods 104 for use
by surgical staff, emergency medical technicians (EMT), emergency
room staff, school nurses, etc. Use of the tab portion 168 can
assist with maintaining sterilization by reducing a user's possible
contact with the pouch 140. Additionally, by providing pre-measured
amounts of a chemical (e.g., medicine, disinfectant, etc.), the
need for measuring devices can be omitted, thereby reducing waste
of the chemical as well as contamination of the measuring device.
The pod 104 can also include other products 106, such as adhesives,
sealants, and lubrication (e.g., grease, glue, oil), thereby
providing a storage and delivery system with a reduced need for a
user to contact such products 106.
[0026] When the product 106 is a food-based product, the use of the
pods 104 allow for pre-portioned servings and can be utilized to
limit exposure of the product 106 to sources of contamination
(bacteria, virus, etc.). For example, assuming an egg shell has
been sterilized, the egg content can be removed from the shell,
then placed in the pods 104, thereby preventing exposure of the egg
content to later introduced contaminants when a user cracks open
the egg for consumption. In at least some embodiments, the cover
150 can include a bubble-shaped reservoir to hold and dispense
liquid. In another embodiment, the cover 150 can include a
mechanism that when the cover 150 is depressed, a secondary liquid
or powder can be released into a primary liquid and then extracted
to a bubble-shaped reservoir, wherein the mixing occurs in a
sterile oxygen-free environment without direct contact by a
user.
[0027] An exemplary method of manufacturing the packaging and
dispensing apparatus 100 includes inserting a product 106 inside
the pouch 140, securing the cover 150 to the upper portion of the
pouch 142 using the adhesive 152 to form the pod 104, wherein the
cover 150 includes a tab layer 166 secured thereto; inserting the
pod 104 into the compartment 120 of the tray 102, injecting a gas
170 inside the compartment 120 to displace oxygen, and sealing the
tray bottom surface 112 to the rim portion 118 of the tray top
surface 110.
[0028] It should be appreciated that the present disclosure is
intended to encompass numerous embodiments as disclosed herein and
further described by the following: [0029] (i). A pod apparatus
comprising: [0030] a pouch for housing a product; [0031] a cover
secured to the pouch to provide closure; and [0032] a tab layer
secured at least partially to the cover to provide a graspable
portion. [0033] (ii). The apparatus of (i), wherein the cover is
formed of a rigid material and the tab layer is formed of a
flexible material. [0034] (iii). The apparatus of any one of
(i-ii), wherein only a portion of the tab layer is removable from
the cover. [0035] (iv) An apparatus comprising: [0036] a tray
having a top surface, a bottom surface, and a sidewall; [0037] one
or more compartments integrally formed with and extending from the
bottom surface of the tray; [0038] one or more pods for housing a
product, the pods further comprising: [0039] a pouch; [0040] a
cover secured to the pouch to provide closure of the pod, the cover
including a bottom cover surface and a top cover surface; and
[0041] a tab layer secured at least partially to the top cover
surface, [0042] wherein the pods are received and at least
partially enclosed by the compartments, and the pods are secured to
the tray. [0043] (v). The apparatus of (iv), wherein the cover
bottom surface is secured to the top surface of the tray. [0044]
(vi). The apparatus of any one of (iv-v), wherein the tab layer
includes a tab portion. [0045] (vii). The apparatus of any one of
(iv-vi), wherein the one or more pods are separable from the tray
by exerting a pulling force on the tab portion. [0046] (viii). The
apparatus of any one of (iv-vii), wherein separation of the one or
pods using the tab portion does not separate the cover from the
pouch. [0047] (ix). A method of packaging goods comprising: [0048]
filling a pouch with a product; [0049] securing the pouch to a
cover to enclose the product, wherein the cover includes a tab
layer secured thereto; [0050] providing a substrate material having
a top surface and one or more compartments extending therefrom;
[0051] positioning the pouch inside a compartment of a tray,
wherein the tray includes a top surface; and [0052] securing the
cover to the tray top surface. [0053] (x). The method of (ix),
further comprising injecting a gas inside the compartment to
substantially displace oxygen in the compartment. It is
specifically intended that the packaging and dispensing apparatus
100 is not limited to the embodiments and illustrations contained
herein, but include modified forms of those embodiments including
portions of the embodiments and combinations of elements of
different embodiments as come within the scope of the following
claims.
* * * * *