U.S. patent application number 14/025245 was filed with the patent office on 2015-03-12 for one-piece food container having an integral hinge with latching mechanisms and a full perimeter seal.
The applicant listed for this patent is Sophie J. Johnson. Invention is credited to Sophie J. Johnson.
Application Number | 20150069064 14/025245 |
Document ID | / |
Family ID | 52624517 |
Filed Date | 2015-03-12 |
United States Patent
Application |
20150069064 |
Kind Code |
A1 |
Johnson; Sophie J. |
March 12, 2015 |
One-Piece Food Container having an Integral Hinge with Latching
Mechanisms and a Full Perimeter Seal
Abstract
The present invention relates to a one-piece food container with
an integral hinge and one or more latching mechanism, a full
perimeter seal, and ribbed or ridged support structures. The food
container is fabricated from hybrid bio-based and polymeric a
material that has heat resistance capabilities. In particular, the
present apparatus and method utilize a hybrid slurry of simple,
abundant and renewable materials, such as food or plant starch and
calcium carbonate (limestone), and a polymeric material, that uses
high temperature and high pressure presses. An optional coating,
such as wax, is applied to the surface of the food container. The
present invention one-piece food container has a plurality of
ridges that are incorporated into the container to provide rigidity
and resisting folding or bending. Lastly, the one-piece food
container with has enough rigidity and strength to be stackable for
efficient storage for distribution to a user. The resulting
one-piece food container is strong, light, heat-resistant, and
attractive.
Inventors: |
Johnson; Sophie J.; (Walnut
Creek, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Johnson; Sophie J. |
Walnut Creek |
CA |
US |
|
|
Family ID: |
52624517 |
Appl. No.: |
14/025245 |
Filed: |
September 12, 2013 |
Current U.S.
Class: |
220/324 |
Current CPC
Class: |
B65D 2251/1033 20130101;
B65D 43/162 20130101; Y02W 90/10 20150501; Y02W 90/11 20150501;
Y02A 40/961 20180101 |
Class at
Publication: |
220/324 |
International
Class: |
B65D 43/16 20060101
B65D043/16; B65D 81/34 20060101 B65D081/34; B65D 43/22 20060101
B65D043/22; B65D 6/00 20060101 B65D006/00 |
Claims
1. A food container comprising: a first food container bottom
portion and a second food container top portion; an integral hinge
mechanism, said integral hinge mechanism connecting said first food
container bottom portion to said second food container top portion;
said first food container bottom portion having a food cavity
section; full perimeter seal, said first food container bottom
having a first perimeter seal configuration, said second food
container top having a second perimeter seal configuration, whereby
said first perimeter seal configuration is designed to removable
engage said second perimeter seal configuration resulting in a full
perimeter seal, said full perimeter seal functions to removably
seal said food cavity section; one or more latching mechanisms,
said one or more latching mechanisms designed removably engage said
first food container bottom portion to said second food container
top portion; one or more first ear tabs extending from said bottom
container bottom portion, said one or more ear tabs off-set to
facilitate separation when said one or more latching mechanisms
removably engage said first food container bottom portion to said
second food container top portion; a plurality of supportive
structural ribbed sections incorporated on said bottom portion,
said supportive structural ribbed sections function to provide
rigidity and strength to said bottom portion; and one or more
supportive structural full perimeter supportive structural ribbed
sections incorporated on said top portion; one or more supportive
structural full perimeter supportive structural ribbed sections
function to provide rigidity and strength to said top portion.
2. A food container as recited in claim 1, whereby said food
container is fabricated from at least a 50 percent bio-based
material remaining percentage of fabrication material is a
polymeric material.
3. A food container as recited in claim 1, whereby said food
container is fabricated from a biodegradable and/or compostable
material.
4. A food container as recited in claim 3, whereby said
biodegradable or compostable fabrication material is a combination
of a food or plant starch and calcium carbonate and said remaining
percentage is a polymeric material.
5. A food container as recited in claim 1, whereby food container
is microwave compatible.
6. A food container as recited in claim 1, whereby food container
is heat resistant within the range of 100-250 degrees
Fahrenheit.
7. A food container as recited in claim 1, wherein said food
container is FDA approved for food containment and delivery.
8. A food container as recited in claim 1, further comprising said
food container is coated with a biodegradable or compostable
coating.
9. A food container as recited in claim 1, whereby said food
container is gluten and GMO-free.
10. A food container as recited in claim 1, whereby said food
container is dishwasher safe.
11. A food container fabricated from at least 50 percent bio-based
material, comprising: a first food container bottom portion and a
second food container top portion; an integral hinge mechanism,
said integral hinge mechanism connecting said first food container
bottom portion to said second food container top portion; said
first food container bottom portion, said second food container top
portion and said hinge mechanism, fabricated from hybrid material
that is at least 50% bio-based; said first food container bottom
portion having a food cavity section; a full perimeter seal, said
first food container bottom having a first perimeter seal
configuration, said second food container top having a second
perimeter seal configuration, whereby said first perimeter seal
configuration is designed to removable engage said second perimeter
seal configuration resulting in a full perimeter seal, said full
perimeter seal functions to removably seal said food cavity
section; one or more latching mechanisms, said one or more latching
mechanisms designed removably engage said first food container
bottom portion to said second food container top portion; one or
more first ear tabs extending from said bottom container bottom
portion, said one or more ear tabs off-set to facilitate separation
when said one or more latching mechanisms removably engage said
first food container bottom portion to said second food container
top portion; a plurality of supportive structural ribbed sections
incorporated on said bottom portion, said supportive structural
ribbed sections function to provide rigidity and strength to said
bottom portion; and one or more supportive structural full
perimeter supportive structural ribbed sections incorporated on
said top portion, one or more supportive structural full perimeter
supportive structural ribbed sections function to provide rigidity
and strength to said top portion.
12. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, whereby the remaining percentage of
fabrication material is a polymeric material
13. A food container as recited in claim 1, whereby said food
container fabricated from at least 50 percent bio-based material is
a biodegradable and/or compostable material.
14. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, whereby said biodegradable or
compostable fabrication material is a combination of a food or
plant starch and calcium carbonate and said remaining percentage is
a polymeric material.
15. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, whereby food container is microwave
compatible.
16. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, whereby food container is heat
resistant within the range of 100-250 degrees Fahrenheit.
17. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, wherein said food container is FDA
approved for food containment and delivery.
18. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, further comprising said food
container is coated with a biodegradable or compostable
coating.
19. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, whereby said food container is
gluten and GMO-free.
20. A food container fabricated from at least 50 percent bio-based
material as recited in claim 1, whereby said food container is
dishwasher safe.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to a food container
apparatus comprised of a hybrid of bio-based and polymeric
materials, and in particular to an one-piece food container
apparatus having a full perimeter seal, integral hinge, one or more
latching mechanisms, ridge support structures and having heat
resistance capability.
BACKGROUND OF THE INVENTION
[0002] A popular type of disposable food container is a hinged
one-piece takeout container having a clamshell configuration. These
containers are typically made by thermoforming a sheet of plastic
or polymeric foam material into two adjacent trays interconnected
by a integral hinge. The two adjacent trays are disposed on either
side of the hinge mechanism and respectively define a bottom
container tray and a top lid tray. The container is held closed by
some type of latching mechanism.
[0003] Hinged one-piece clamshell containers may be constructed
from foam materials including expanded polystyrene commonly known
as Styrofoam. The latching mechanism on foam clamshell containers
typically comprises at least one tab-shaped projection incorporated
into the top lid tray that engages with a corresponding slot or
recess in the bottom container tray. Foam clamshell containers are
one of the cheapest solutions of the industry and are not
considered environmentally conscious.
[0004] A disadvantage of one-piece hinged takeout containers is
that they are somewhat cumbersome to handle. In their open
configuration the attached lid and the bottom tray of a typical
one-piece hinged takeout container almost doubles in size and
occupies a large area on the eating surface. Also, the typical
fabrication materials for the one-piece container package does not
convey to the consumer an environmentally conscious resource, is
wasteful, and is responsible for a high volume of waste that is
filing up waste disposal dumping sites at an ever increasing pace.
In addition, most one-piece or clamshell containers are not heat
resistant and therefore cannot be use in a oven environment or used
with hot food.
[0005] Nonetheless, the one piece hinged container has several
advantages because it obviates the need to stock multiple
components for each size and shape which avoids the risk of running
out of one of the container components. In addition, using a
one-piece hinged containers eliminate the problem associated with
incorrect lid sizes.
[0006] Due to some of the inherent disadvantages of one-piece
containers and their materials of construction, which are generally
viewed as a cheap, non-upscale, dining ware.
[0007] Two-piece containers typically comprise a bottom tray or
base that can be sealed against, or at least engaged, with a top
cooperating lid or cover. The base usually has an upwardly
projecting sidewall terminating into a rim. The inside surface of
the lid is configured to fit around the outside surface of the base
and may have an increased shaped central portion to accommodate an
increase in food volume within the base. Some two-piece contains
utilize a base tray or unit that have a heat-sealed or adhesive
sealed thin plastic lid that is pulled away from the bottom tray to
expose the food contained inside. Generally once the thin plastic
lid is removed, it cannot be used to re-seal the bottom tray.
[0008] One of the problems with two-piece containers is that the
food establishment has to store at least two separate items in the
form of a base container and its corresponding cover or lid. Thus,
a food establishment ends up storing both container bases and lids
for each container size and container type with all the risk of
running short of one item or getting the wrong lid or having a
ill-fitting lid. And if the thin plastic lid is utilized, a sealing
machine must be maintained on-site for meeting the purpose of
sealing food inside the bottom tray for service or delivery.
[0009] In addition, two-piece containers are generally held
together by closure mechanisms that rely generally on an effective
friction fit between the outside surface of the container and the
inside surface of the lid. Often times the closure mechanism is not
secure enough for general carrying convenience and take-out
situations.
[0010] Disposable food dishes and food service containers are
increasingly being used in today's society as it is convenient for
environmental conscious needs. The food dishes and food containers
are generally used a single time and then disposed of by the user.
But typical food service dishes and containers formed of plastic
polymer materials, such as polystyrene (Styrofoam) or other
plastic, which does not biodegrade significantly. Food service
products may also be formed of paper. However, such paper is
frequently coated with a plastic coating, also making it resistant
to biodegrading.
[0011] It would be a benefit if disposable food dishes were formed
of at least 50% bio-based material and the remaining percentage of
a polymeric material that could have biodegradable or compostable
capabilities, especially if such material is a renewable resource.
The manufacturing of such food service items should be as efficient
as possible in order to provide reliable, low cost production at
competitive pricing and meet the goal of using fabrication
renewable bio-based materials.
SUMMARY OF THE INVENTION
[0012] The present invention relates to a one-piece food container
with an integral hinge and one or more latching mechanisms, a full
perimeter seal, a plurality of ridge support structures and
fabricated from a hybrid bio-based and polymeric material that has
heat resistance, and alternately may be biodegradable and/or
compostable. The one-piece food container has a bottom portion and
top portion that are joined together with the integral hinge. In
the preferred embodiment, the one-piece food container has two
latching mechanisms that engage together to removably secure the
top portion to the bottom portion. There is also a pair of ear tabs
near the outer edge of the top and bottom portion that are offset
and are designed to facilitate the separation of the latching
mechanism engaged top and bottom portions. The one-piece food
container also has a plurality of ridges that are incorporated into
strategic locations both on the top and bottom portions to provide
rigidity and resisting folding or bending.
[0013] Regarding the fabrication process, the present invention
one-piece food container utilizes a hybrid bio-based and polymeric
material. The fabrication process starts with a hybrid slurry of
simple, abundant and renewable materials, such as food or plant
starch and calcium carbonate (limestone) and a percentage of common
polymeric materials that are formed into the present invention food
containers using high temperature and high pressure presses. The
hybrid slurry is molded into shape and once molded, the molded food
containers are subjected to a trimming process. After being
trimmed, the food containers are optionally subjected to another
process for coating the food contacting surfaces with a
biodegradable film. An optional further step provides a coating,
such as wax, to the surface of the plate, dish or food container
opposite the film. Lastly, the one-piece food container has enough
rigidity and strength to be stackable for efficient storage for
distribution to a user. The resulting one-piece food container is
strong, light, heat-resistant, and attractive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a inside open perspective view of the one-piece
food container having an integral hinge with one or more latching
mechanisms including full perimeter seal and showing in more detail
a ribbing or ridge structure that provides superior rigidity and
structural support.
[0015] FIG. 1B is a copy of a picture of the food container having
an integral hinge with one or more latching mechanism and a full
perimeter seal in an inside view open configuration.
[0016] FIG. 2 is a top open perspective view of the food container
having an integral hinge with one or more latching mechanisms and a
full perimeter seal.
[0017] FIG. 3 is a bottom open perspective view of the food
container having an integral hinge with one or more latching
mechanisms and a full perimeter seal.
[0018] FIG. 4 is a top closed perspective view of the food
container having an integral hinge with one or more latching
mechanisms and a full perimeter seal.
[0019] FIG. 5 is a back side closed perspective view of the food
container having an integral hinge with one or more latching
mechanisms and a full perimeter seal.
[0020] FIG. 6 is a front side closed perspective view of the food
container having an integral hinge with one or more latching
mechanisms and a full perimeter seal.
[0021] FIG. 7 is a side closed perspective view of the food
container having an integral hinge with one or more latching
mechanisms and a full perimeter seal.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Now referring to FIG. 1, which shows the one-piece inside
open perspective view of the food container having an integral
hinge 12 with one or more latching mechanisms 22a, 22b, 24a, 24b
and including full perimeter seal 30, 32 whereby the food container
is fabricated from hybrid bio-based and polymeric material and also
showing in more detail a ribbing or ridge supports that provide
superior rigidity and structural support. The bottom food portion
container 14 forms a one-piece configuration by securing the top
food portion 16 with an integral hinge mechanism 12 located on the
back of the food container. The bottom food contain portion 14 has
a right opening ear tab 18a and a left opening ear tab 18b. On the
top food container portion 16 there is a corresponding right
opening ear tab 20a and a left opening ear tab 20b. When the top
food container portion 16 is closed onto the bottom food contain
portion 14, the corresponding ear tabs come together were a portion
is off-set such that an individual can separate and pull apart the
ears to facilitate opening the present invention container when the
top and bottom latching mechanisms are engaged.
[0023] The bottom food container portion 14 has a right bottom
latching mechanism 22a that has a protruding portion designed to
removably engage the right top concave or depressed portion 22b. On
the other side, the bottom food container portion 14 has a left
bottom latching mechanism 24a that has a protruding portion
designed to removably engage the left top concave or depressed
portion 24b. It is anticipated by the Applicant that a single
removable latching mechanism, or more than two, could be used with
the present invention food container. In addition, the location of
the top and corresponding bottom latches car be located in
different positions along the outer edge of the top and bottom
portions. Additionally shown is a protruding full perimeter sealing
ridge 30 that encircles the entire perimeter of the bottom food
container portion 14. Also shown is that the right bottom 22a and
left bottom 24a protruding latching portions become integrated with
the protruding full perimeter sealing ridge 30. Also shown is a
plurality of left bottom side rib supporting structures 38 and a
plurality of back bottom rib supporting structures 40. Contained
with the bottom food container portion 14 is the food storage
cavity 42.
[0024] Now addressing only the top food container portion 16, the
Figure shows a full perimeter receiving channel or groove 32 as a
part of full perimeter sealing mechanism. On the outside surface of
the full perimeter receiving channel or groove 32 is a top portion
reinforcing perimeter ridge 34 and a plurality of top portion
perimeter ridge protruding tabs 36. The top portion 16 also has a
right dimple-configured stop 44 and a left dimple-configured stop
46.
[0025] The present invention food container 10 having an integral
hinge 12 with one or more latching mechanisms 22a, 22b, 24a and 24b
and including full perimeter seal 30, 32 whereby the food container
is fabricated from a hybrid slurry of simple, abundant and
renewable materials, such as food or plant starch and calcium
carbonate (limestone) and percentage of common polymer that are
formed into food containers using high temperature and high
pressure press. The bio-based material is defined as a material
made from substances derived from living (or once-living)
organisms. This definition could include many common materials such
as wood and leather, but it typically refers to modern materials
that have undergone more extensive processing. Bio-based materials
are often biodegradable, but this is not always the case. Some
examples of bio-based materials include, but are not limited to,
cellulose fibers, casein poly-lactic acid, bio-plastics (including
soy, oil-based plastics) engineered wood-products (such as oriented
strand board and particle board), zein (natural biopolymer which is
abundant corn protein), cornstarch, plant starches and potato
derivatives. Polymeric component materials may be petroleum based
or soybean based.
[0026] During production, the present invention food container
utilizes a hybrid slurry made according to a specific recipe that
combines at least 50% of a bio-based material comprising calcium
carbonate (limestone), starches such as potatoes and an amount of
fiber, which may include recycled fibers, along with water, and the
remaining percentage comprising a polymeric material. It is
anticipated by the Applicant the other recipes with different
bio-base materials, and different percentages of the
bio-based/polymeric formulas, can be utilized with the present
invention food container. In production, a quantity of the hybrid
slurry is placed into a specifically configured top and bottom mold
cavity. The mold is closed and the hybrid slurry is treated with
high pressure press and exposed to a high temperature for baking.
For example, the high pressure press can be a 120 ton press,
although this is dependent on the product design and matrix of
molds. The heat is controlled by a heat control system specifically
designed for the high pressure press. Once the container product is
formed in the mold, the mold is opened and the product removed. The
molded products are removed from the molds and are trimmed for
removing flashing. After being trimmed, the food containers may be
transferred to another station for alternately coating the food
contacting surfaces with a biodegradable film. An optional further
step provides a wax or other coating to the surface of the food
container.
[0027] The hybrid slurry and final food container product material
is primarily sourced from a renewal source, gluten and GMO-free,
and FDA approved for food use. The final food container product can
be used in a microwave, is dishwasher safe, and is heat-resistant
in a range of 100-250 degrees Fahrenheit. Moisture resistance and
insulation properties are generally very good to excellent when
compared to other common disposable tableware materials.
[0028] The present invention one-piece food container has a
plurality of ridges that are incorporated into strategic locations
on the top and bottom portions of the container to provide rigidity
and resisting folding or bending. Lastly, the one-piece food
container with an integral hinge and one or more latches, a full
perimeter seal, and fabricated from a hybrid bio-based and
polymeric material that has heat resistance capabilities and has
enough rigidity and strength to be stackable for efficient storage
for distribution to a user. The resulting one-piece food container
is strong, light, heat-resistant, and attractive.
[0029] FIG. 1B copy of a picture of the present invention food
container 10 having an integral hinge with one or more seals and a
full perimeter seal that is fabricated from hybrid bio-based and
polymeric material in an inside view open configuration. Shown in
the bottom food container portion 12 are the right 22a and the left
24a protruding latching mechanisms, the food storage cavity 42. The
top food container portion 16 shows the receiving channel or groove
full perimeter seal 32, and the right top concave or depressed
latching mechanism 22b and left top concave or depressed latching
mechanism 24b. Connecting the bottom food container portion 14 to
the top food container portion 16 is the integral hinge mechanism
12.
[0030] FIG. 2 is a top open perspective view of the food container
14 (on the bottom of the figure) having an integral hinge 12 with
one or more latching mechanisms 22a, 22b, 24a, 24b, and a full
perimeter seal 30, 32 that is fabricated from a hybrid bio-based
and polymeric material. Shown on the bottom food container portion
14 is the plurality of bottom right 22a and left 24a latching
mechanisms and a bottom right ear tab 18a and a bottom left ear tab
20a. Within the bottom food container portion 14 is the food
storage cavity 42. Also shown is the plurality of right 38a left
38b bottom side rib supporting structures, a plurality of front
bottom rib supporting structures 41 and a plurality of back bottom
rib supporting structures 40. Since most of the weight of the food
is contained with the cavity 42, the bottom food container portion
14 utilizes the rib supporting structures to maintain the integrity
of the container. Also shown is the protruding full perimeter seal
30 on the bottom food container portion 14.
[0031] Further in FIG. 2, the top food container portion 16 (on the
top of the figure) has a right concave or depressed latching
mechanism 22b and a left concave or depressed latching mechanism
24b and a top right 18b and left 20b ear tabs. Top food container
portion 16 has a full perimeter receiving channel or groove 32 that
functions as a part of full perimeter sealing mechanism. On the
outside surface of the full perimeter receiving channel or groove
32 is a top portion reinforcing perimeter ridge 34 and a plurality
of top portion perimeter ridge protruding tabs 36. The top portion
16 also has a right dimple-configured stop 44 and a left
dimple-configured stop 46.
[0032] FIG. 3 is a bottom open perspective view of the food
container 10 having an integral hinge 12 with one or more latching
mechanisms and a full perimeter seal that is fabricated from a
hybrid bio-based and polymeric material. The bottom food container
portion 14 (on the top of the figure) shows the right ear tab 18a
and the left ear tab 20a. Also shown is the bottom surface of the
right latching mechanism 50a and the bottom surface of the left
latching mechanism 50b. The bottom surfaces 50a and 50b have a
concave or depressed configuration as the other corresponding
surface forms the protruding surfaces. Also shown is the plurality
of right 38a left 38b bottom side rib supporting structures, a
plurality of front bottom rib supporting structures 41 and a
plurality of back bottom rib supporting structures 40.
[0033] Further in FIG. 3, the top bottom food container portion 16
shows the top right ear tab 18b and the top left ear tab 20b and
the top outside surface 17 of the food container portion 16. The
right stop 44b and dimple stop 46b are concave or depressed shaped
in this side as the corresponding dimple stops form the protruding
dimples on the other side. A full perimeter reinforcing structure
56 is also shown. The right top latching mechanism 52a and the left
top latching mechanism 52b protrude out from the top surface as the
corresponding right and left latching mechanism are concave or
depressed.
[0034] Connecting the bottom food container portion 14 to the top
food container portion 16 is the integral hinge mechanism 12.
[0035] FIG. 4 is a top closed perspective view of the food
container 10 having an integral hinge 12 with one or more latching
mechanisms 58, 60 and a full perimeter seal fabricated from a
hybrid bio-based and polymeric material. Shown in the closed
configuration are the offset right top 20a and bottom 18a ear tabs
and the offset left top 18b and bottom 20b ear tabs and the top
outside surface 17 of the food container portion 16. The integral
hinge mechanism 12 connects the top food container portion 16 to
the bottom food container portion 14. When the food container is in
a closed configuration the top right and the bottom right latching
mechanism become removably engaged 60 and the top left and bottom
left latching mechanism become removably engaged 58.
[0036] FIG. 5 is a back side closed perspective view of the food
container 10 having an integral hinge 12 with one or more latching
mechanisms and a full perimeter seal fabricated from a hybrid
bio-based and polymeric material. Shown in this Figure is the
bottom back side rib supporting structures 40, the bottom food
container portion 14 and the top outside food container portion
surface 17.
[0037] FIG. 6 is a front side closed perspective view of the food
container 10 having an integral hinge 12 with one or more latching
mechanisms 58, 60 and a full perimeter seal fabricated from a
hybrid bio-based and polymeric material. Shown in this Figure are
the engaged latching mechanisms 58 and 60, the bottom food
container portion 14 with front bottom side rib supporting
structures 41, the and the top outside surface 17 of the food
container portion 16, and engaged dimple stop 46a.
[0038] FIG. 7 is a side closed perspective view of the food
container 10 having an integral hinge 12 with one or more latching
mechanisms 58, 60 and a full perimeter seal fabricated from a
hybrid bio-based and polymeric material. In this Figure, shown is
the bottom food container portion 14 with side rib support
structures 38a and top outside surface 17 of the food container
portion 16. Also shown are engaged right 44 and left 56 dimple
protruding stops.
* * * * *