U.S. patent application number 14/050109 was filed with the patent office on 2015-04-09 for expandable food package with lid.
This patent application is currently assigned to The Quaker Oats Company. The applicant listed for this patent is The Quaker Oats Company. Invention is credited to Eric Thomas HENDERSON, James J. MAKI.
Application Number | 20150096978 14/050109 |
Document ID | / |
Family ID | 52776149 |
Filed Date | 2015-04-09 |
United States Patent
Application |
20150096978 |
Kind Code |
A1 |
HENDERSON; Eric Thomas ; et
al. |
April 9, 2015 |
EXPANDABLE FOOD PACKAGE WITH LID
Abstract
An expandable food package with a removable lid, is provided.
The food package has a bottom, an inner sidewall and an outer
sidewall. The inner sidewall and outer sidewall are connected by a
series of living hinges that allow the package to be converted
between an expanded configuration and collapsed configuration. A
lid may be sealed to one or both of an inner rim and an outer rim
when the package is in collapsed configuration.
Inventors: |
HENDERSON; Eric Thomas;
(Chicago, IL) ; MAKI; James J.; (McHenry,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Quaker Oats Company |
Chicago |
IL |
US |
|
|
Assignee: |
The Quaker Oats Company
Chicago
IL
|
Family ID: |
52776149 |
Appl. No.: |
14/050109 |
Filed: |
October 9, 2013 |
Current U.S.
Class: |
220/8 ;
53/471 |
Current CPC
Class: |
B65B 3/00 20130101; B65D
21/086 20130101; B65D 77/2024 20130101; B65D 81/3453 20130101; B65D
2577/205 20130101 |
Class at
Publication: |
220/8 ;
53/471 |
International
Class: |
B65D 6/16 20060101
B65D006/16; B65B 3/00 20060101 B65B003/00; B65D 8/00 20060101
B65D008/00 |
Claims
1. An expandable food package comprising: a bottom; an inner
sidewall extending upward from said bottom; a series of at least
two living hinges connecting said inner side wall with an outer
sidewall, wherein an inner rim is defined by an intersection
between said inner sidewall and a first living hinge in said series
of living hinges, wherein said outer side wall defines an outer rim
on a side opposite a second living hinge in said series of living
hinges; and a lid affixed to said inner rim or said outer rim.
2. The food package of claim 1 wherein said lid is affixed to said
inner rim by a first seal and to said outer rim by a second
seal.
3. The food package of claim 1 wherein said series comprises at
least four living hinges.
4. The food package of claim 1 wherein each said living hinge
comprises an angle of orientation, the angle of orientation for
each living hinge is opposite the angle of orientation for each
adjacent living hinge.
5. The food package of claim 1 further comprising a lower rim
defined at the intersection of said outer rim and said second
living hinge, wherein said lower rim is approximately coplanar with
said bottom.
6. The food package of claim 1 wherein said inner rim and said
outer rim are approximately coplanar.
7. The food package of claim 1 wherein said bottom is approximately
circular.
8. A method of packaging a food product comprising: providing an
expandable bowl portion of a food package in collapsed
configuration, said bowl portion comprising: a bottom; an inner
sidewall extending upward from said bottom; a series of at least
two living hinges connecting said inner side wall with an outer
sidewall, wherein an inner rim is defined by an intersection
between said inner sidewall and a first living hinge in said series
of living hinges, wherein said outer side wall defines an outer rim
on a side opposite a second living hinge in said series of living
hinges; at least partially filling a compartment defined by said
bottom and said inner sidewall with said food product; and affixing
a lid to said inner rim or said outer rim.
9. The method of claim 8 wherein said affixing step further
comprises affixing said lid to said inner rim by a first seal and
to said outer rim by a second seal.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a food package that is
expandable, which may have a lid, and method of making the food
package.
[0003] 2. Description Of Related Art
[0004] The food industry markets some food products in packages
that comprise a base and a lid sealed onto the base. The base
generally comprises a bowl or other liquid retaining shape with a
rim, and a lid is typically sealed along the rim of the base. An
example of such a known bowl is depicted in FIG. 1. The bowl
depicted in FIG. 1 comprises a base 102 and a lid 104 affixed to
the base along the rim 106 of the base. Foods that are sold in such
packaging include chili, soup, cheese sauce, salsa, dips, oats,
oatmeal and other mixtures of solid and/or liquid food products.
Foods that are packaged in this way are often consumed directly
from the base after the lid is removed.
[0005] Additionally, many such packaged foods are intended to be
consumed or cooked at elevated temperatures prior to consumption.
Microwave ovens are commonly used to heat such food products. The
microwave oven is an appliance that can be found in many homes and
businesses. During operation, a microwave oven floods the cooking
chamber with non-ionizing microwave radiation, usually at a
frequency of about 2.45 GHz. Many food molecules (for example water
molecules) are electric dipoles, which means they are positively
charged at one end and a negatively charged at the other end. As
the microwave radiation passes through the food, the dipole
molecules rotate as they try to align themselves with the
alternating electric field of the microwaves. This rotation and
movement causes the food to heat up as the rotating molecules
impact other molecules, putting them into motion. Microwave heating
is highly efficient on liquid water (which a relatively polar
molecule), and much less so on fats and sugars (which are less
polar).
[0006] However, heating food inside a food package described above
with a water-containing food or food product inside can cause
problems. Most such packaged foods are packaged with a "headspace."
The headspace is the region between the food inside the food
package and the lid. The headspace allows for room between the
upper level of the food inside the package and the upper rim of the
bowl to prevent spillover when the food is heated. The disadvantage
to providing enough headspace to guard against spillover is that it
increases shipping costs for the food container by reducing the
density of both the food package itself and larger groupings or
cartons of food packages.
[0007] The main solution to this problem in the prior art is to
provide a food package with smaller headspace with instructions to
the consumer to pour the food into a separate microwave safe bowl
with adequate spillover protection before heating it in the
microwave. This approach is problematic for several reasons. First,
the consumer may not transfer the food as instructed because he or
she did not read, forgot to follow, or chose not to follow the
instructions provided. Second, the consumer is inconvenienced by
this prior art solution.
[0008] Consequently, a need exists for a food product package that
can be shipped with minimal headspace and expanded before being
heated in a microwave oven.
SUMMARY OF THE INVENTION
[0009] The present invention is a food package that is expandable
prior to heating or consumption of the food. In one embodiment, an
expandable food package comprises a bottom, an inner sidewall
extending upward from said bottom, a series of at least two living
hinges connecting said inner side wall with an outer sidewall,
wherein an inner rim is defined by an intersection between said
inner sidewall and a first living hinge in said series of living
hinges, wherein said outer side wall defines an outer rim on a side
opposite a second living hinge in said series of living hinges, and
a lid affixed to said inner rim or said outer rim.
[0010] In another embodiment, the lid is affixed to the inner rim
by a first seal and to the outer rim by a second seal. In one
embodiment, the series comprises at least four living hinges. In
still another embodiment, each said living hinge comprises an angle
of orientation, the angle of orientation for each living hinge is
opposite the angle of orientation for each adjacent living
hinge.
[0011] In one embodiment, the food package further comprises a
lower rim defined at the intersection of said outer rim and said
second living hinge, wherein said lower rim is approximately
coplanar with said bottom. The inner rim and outer rim may be
approximately coplanar. The bottom of the food package is
preferably approximately circular.
[0012] In one embodiment, a method of packaging a food product
comprises providing an expandable bowl portion of a food package in
collapsed configuration, said bowl portion comprising: a bottom; an
inner sidewall extending upward from said bottom; a series of at
least two living hinges connecting said inner side wall with an
outer sidewall, wherein an inner rim is defined by an intersection
between said inner sidewall and a first living hinge in said series
of living hinges, wherein said outer side wall defines an outer rim
on a side opposite a second living hinge in said series of living
hinges; at least partially filling a compartment defined by said
bottom and said inner sidewall with said food product; and affixing
a lid to said inner rim or said outer rim. In another embodiment,
the affixing step further comprises affixing said lid to said inner
rim by a first seal and to said outer rim by a second seal.
[0013] The resultant food product package is relatively simple and
inexpensive to manufacture, yet overcomes the problems in the prior
art by allowing the food package to be expanded prior to heating or
consumption. The above as well as additional features and
advantages of the present invention will become apparent in the
following written detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The novel features believed characteristic of the invention
are set forth in the appended claims. The invention itself,
however, as well as a preferred mode of use, further objectives and
advantages thereof, will be best understood by reference to the
following detailed description of illustrative embodiments when
read in conjunction with the accompanying drawings, wherein:
[0015] FIG. 1 is a perspective view of a prior art food
package;
[0016] FIG. 2 is a perspective view of one embodiment of the
present invention comprising an expandable bowl with a lid sealed
at an inner rim;
[0017] FIG. 3 is a perspective view of the bowl depicted in FIG. 2
but in expanded configuration;
[0018] FIG. 4 is a cross sectional view of one embodiment of the
present invention in collapsed configuration;
[0019] FIG. 5 is a frontal view of one embodiment of the present
invention in expanded configuration.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] The present invention is directed towards a food package
that is expandable prior to heating in a in a microwave oven and
method of making the same. The term "food package" as used herein
is defined as a package designed to contain food inside of it. The
type of food package that usually stores food products intended to
be heated in a microwave or consumed from a package having a cup or
bowl shape comprises a sturdy, bowl-shaped base with a lid sealed
to the rim of the base. However, the principles of the present
invention in its broadest sense are applicable to any food package
containing a food product.
[0021] Referring to FIG. 1, therein is depicted a prior art food
package 100 comprising a bowl-shaped base 102, a lid 104 and a seal
holding the lid 104 onto the base 102 along its rim 106. The seal
can be created using any heat activated sealant known in the
industry, including polypropylene based sealants.
[0022] If the food package of FIG. 1 contains a food product
intended to be heated in a microwave oven, it may fill
approximately the bottom one-third of the package, leaving enough
headspace that water can be added if necessary, such that the
container walls can still guard against spillover during
heating.
[0023] FIG. 2 depicts one embodiment of the food package of the
present invention in collapsed configuration, and FIG. 3 depicts
the same embodiment in expanded configuration, without a lid and
partially filled with a food product. A lid will typically be used
to seal the food package in collapsed and/or expanded
configuration.
[0024] The features of this embodiment are most clearly depicted in
FIG. 3. Therein is shown a bottom 202, typically planar surface on
which the food package rests when placed on a resting surface.
Extending upward from the bottom 202 is an inner sidewall 204. In a
preferred embodiment, a cross section of the inner sidewall taken
parallel to the bottom surface will be approximately circular in
shape. FIG. 3 also depicts a series of living hinges 206 that
connect the upper end of the inner sidewall to the lower end of an
outer sidewall 208. When the horizontal cross sections of the inner
and outer sidewalls are approximately circular or annular in shape,
the living hinges will also be circular or annular.
[0025] The series of living hinges 206 comprises at least two
living hinges, preferably at least four, and more preferably at
least six. Regardless of the number, each living hinge opens and
closes in a direction opposite to each adjacent living hinge in the
series. In other words, the angle of rotation for each living hinge
is oriented in a direction opposite of the angle of rotation for
each adjacent living hinge. The resulting structure is similar to
bellows.
[0026] Also depicted in FIG. 3 is an outer sidewall 208 that
extends upward from the living hinge located furthest from the
inner sidewall. The outer sidewall defines an upper rim 210 on the
side opposite the living hinge connected to it. When the package is
in expanded configuration (FIG. 3), the interior volume is
substantially higher than the interior volume of the package in
collapsed configuration (FIG. 2).
[0027] FIG. 4 depicts a cross-sectional view of one embodiment of
the present invention in collapsed configuration. In this
embodiment, food (not shown) can be stored within the compartment
defined by the bottom 202, the inner sidewall 204, and the lid 212.
The lid can be affixed to one or both of the inner rim 214 (defined
by the intersection of the inner sidewall 204 and the adjacent
living hinge in living hinge series 206) and the outer rim 210
(defined by the end of the outer sidewall 208 opposite the living
hinge series 206).
[0028] As depicted in FIG. 4, in a preferred embodiment the lower
rim 216 (defined by the intersection of the outer side wall 208 and
the living hinge adjacent to the outer side wall in the living
hinge series 206) is approximately coplanar with the bottom surface
202. Additionally, the inner rim and outer rim are preferably
approximately coplanar. This arrangement allows for the most
height-efficient package possible because, as depicted in FIG. 5,
the package can be expanded to an expanded configuration that is
approximately three times the height of the collapsed
configuration, and has a substantially increased interior
volume.
[0029] In a preferred embodiment, the expandable bowl is produced
by blow molding a polymer resin into the desired shape. Preferred
polymers include polyethylene and polypropylene, but may be any
polymer or polymer blend that is compatible with a blow molding
process. The bowl may also be injection molded, or fabricated from
cardboard, paperboard or other cellulose or fiber-based
process.
[0030] In the most preferred embodiment, the bowl is manufactured
in collapsed configuration. If it is not manufactured in collapsed
configuration, the base is collapsed and then filled with food
product. Alternatively, the base may be filled with food product
before being collapsed. In any case, the collapsed, filled food
package is capped with a lid.
[0031] The lid is preferably a polymer lid. The lid optionally
includes a barrier layer, such as a metalized coating. The lid may
also be a paper or metalized paper lid, or a metal foil lid. The
lid is preferably affixed to one or both of the outer rim or the
inner rim with a sealant that allows a consumer to peel the lid off
the container when it is desired to do so. Preferably, the sealant
is a heat activated sealant. In one embodiment a heat activated
sealant that can be used to affix the lid to the bowl is a low
density polyethylene (LDPE)/high density polyethylene (HDPE)
coextrusion, or a polypropylene/ethylene vinyl alcohol (EVOH)
coextrusion. Alternatively, a pressure-activated sealant can be
used.
[0032] The reduced headspace in the compartment defined by the
bottom, inner sidewall and lid give the food package of the present
invention several advantages over the prior art. First, the reduced
packing density allows more food product and food packages to be
stored and shipped in a given volume. This reduces per unit
shipping costs, and reduces the amount of space the package
occupies in commercial warehouses, store shelves, and consumer
pantries. The reduced volume of gas contained inside the package
can also help extend shelf life because there will be less oxygen
contained initially inside the container available to contribute to
food spoilation.
[0033] While this invention has been particularly shown and
described the preference to the preferred embodiment, it will be
understood by those skilled in the art that changes in form and
detail may be made therein without departing from the spirit and
scope of the invention.
* * * * *