U.S. patent application number 14/770558 was filed with the patent office on 2016-01-21 for resealable leak-resistant containers having a pressed pulp tray with a thermoformed plastic lid.
The applicant listed for this patent is SABERT CORPORATION. Invention is credited to Ron SEIDEL, Yohanan SISKINDOVICH.
Application Number | 20160016702 14/770558 |
Document ID | / |
Family ID | 51537650 |
Filed Date | 2016-01-21 |
United States Patent
Application |
20160016702 |
Kind Code |
A1 |
SISKINDOVICH; Yohanan ; et
al. |
January 21, 2016 |
Resealable Leak-Resistant Containers Having A Pressed Pulp Tray
With A Thermoformed Plastic Lid
Abstract
A leak-resistant pulp container with a plastic lid is disclosed,
including a tray formed of molded pulp and having a boom and a
sidewall forming an interior volume. The tray has an edge extending
peripherally outward from an upper edge of the sidewall, and the
tray edge has an outer portion. The container further includes a
plastic lid having an edge extending peripherally outward
therefrom, and the lid edge having an outer portion.
Inventors: |
SISKINDOVICH; Yohanan; (Glen
Ridge, NJ) ; SEIDEL; Ron; (Middletown, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SABERT CORPORATION |
Sayreville |
NJ |
US |
|
|
Family ID: |
51537650 |
Appl. No.: |
14/770558 |
Filed: |
March 14, 2014 |
PCT Filed: |
March 14, 2014 |
PCT NO: |
PCT/US14/28541 |
371 Date: |
August 26, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61799008 |
Mar 15, 2013 |
|
|
|
Current U.S.
Class: |
220/315 |
Current CPC
Class: |
B65D 2543/00296
20130101; B65D 2543/00796 20130101; B65D 2543/00083 20130101; B65D
2543/00351 20130101; B65D 2543/00537 20130101; B65D 2543/00731
20130101; B65D 2543/00203 20130101; B65D 2543/00407 20130101; B65D
2543/00361 20130101; B65D 2543/00648 20130101; B65D 2543/00462
20130101; B65D 43/065 20130101; B65D 43/0208 20130101; B65D
2543/00416 20130101; B65D 2543/00092 20130101; B65D 2543/00555
20130101; B65D 2543/00509 20130101; B65D 2543/00268 20130101; B65D
2543/00685 20130101; B65D 2543/00101 20130101 |
International
Class: |
B65D 43/06 20060101
B65D043/06; B65D 43/02 20060101 B65D043/02 |
Claims
1. A leak-resistant pulp container with a plastic lid, comprising:
a tray formed of molded pulp and having a bottom and a sidewall
forming an interior volume, the tray further comprising an edge
extending peripherally outward from an upper edge of the sidewall,
the tray edge having an outer portion; and a plastic lid having an
edge extending peripherally outward therefrom, the lid edge having
an outer portion, wherein the lid edge and the tray edge each has a
corresponding peripheral channel configured so that one of the
peripheral channels is received in the other of the peripheral
channels to secure the lid to the tray, each of the peripheral
channels comprising an inner wall and an outer wall joined by a
horizontal channel wall, and wherein the outer wall of the
peripheral channel of the lid edge has a protrusion which mates
with the outer portion of the tray edge to create an interference
fit between the lid edge and the tray edge to secure the lid to the
tray.
2. The leak-resistant pulp container of claim 1, wherein the inner
wall of the peripheral channel of the tray edge has a sealing
surface which presses against a corresponding sealing surface of
the inner wall of the peripheral channel of the lid edge when the
lid is secured to the tray, thereby forming a leak-resistant seal
between the lid edge and the tray edge.
3. The leak-resistant pulp container of claim 2, wherein the lid
edge is configured so that the outer wall of the peripheral channel
of the lid edge applies force to the outer portion of the tray edge
to force the sealing surface of the tray edge against the sealing
surface of the lid edge.
4. The leak-resistant pulp container of claim 2, wherein sealing
surfaces of the lid edge and the tray edge extend to include at
least a portion of the horizontal channel walls of the lid edge and
the tray edge.
5. The leak-resistant pulp container of claim 2, wherein the inner
wall of the peripheral channel of the lid edge and the inner wall
of the peripheral channel of the tray edge are dimensioned to at
least partially overlap in a cross-sectional plane, thereby forcing
the sealing surface of the tray edge against the sealing surface of
the lid edge when the lid is secured to the tray.
6. The leak-resistant pulp container of claim 1, wherein the
protrusion of the outer wall of the peripheral channel of the lid
edge has a lower lip which extends inward to keep the outer portion
of the tray edge in place in the protrusion, thereby acting to
secure the lid to the tray.
7. The leak-resistant pulp container of claim 6, wherein the lower
lip of the protrusion of the outer wall of the peripheral channel
of the lid edge is formed in separate peripheral segments around
the periphery of the lid.
8. The leak-resistant pulp container of claim 1, wherein inner wall
of the peripheral channel of the tray edge forms a draft angle with
respect to a vertical direction of the container, when upright, of
between about 8 degrees and about 12 degrees.
9. The leak-resistant pulp container of claim 8, wherein the draft
angle of the inner wall of the peripheral channel of the tray edge
is between about 10 degrees and about 12 degrees.
10. The leak-resistant pulp container of claim 1, wherein the outer
portion of the tray edge is substantially flat in a horizontal
plane of the container when upright.
11. The leak-resistant pulp container of claim 1, wherein a tab
extends from the lid edge and beyond the tray edge.
12. The leak-resistant pulp container of claim 1, wherein the tray
and the lid each has a substantially oval shape.
13. The leak-resistant pulp container of claim 1, wherein the lid
is formed of any of the following plastic materials: high density
polyethylene (HDPE), polyethylene terephthalate (PET),
polypropylene (PP), polystyrene (PS), and polylactic acid
(PLA).
14. The leak-resistant pulp container of claim 1, wherein the lid
is formed by a thermoforming process.
15. The leak-resistant pulp container of claim 1, wherein the lid
is formed by an injection molding process.
16. A leak-resistant pulp container with a plastic lid, comprising:
a tray formed of molded pulp and having a bottom and a sidewall
forming an interior volume, the tray further comprising an edge
extending peripherally outward from an upper edge of the sidewall,
the tray edge having an outer portion; and a plastic lid having an
edge extending peripherally outward therefrom, the lid edge having
an outer portion, wherein the lid edge and the tray edge each has a
corresponding lock portion configured so that one of the lock
portions mates with the other of the lock portions to secure the
lid to the tray, and wherein the lid edge and the tray edge each
has a corresponding seal portion configured so that one of the seal
portions presses against the other of the seal portions when the
lid is secured to the tray, thereby forming a leak-resistant seal
between the lid edge and the tray edge.
17. The leak-resistant pulp container of claim 16, wherein the seal
portions of the lid edge and the tray edge are formed in an inner
portion of the lid edge and the tray edge with respect to the lock
portions of the lid edge and the tray edge.
18. The leak-resistant pulp container of claim 16, wherein the lock
portion of the lid edge comprises an outer wall having a protrusion
which mates with the outer portion of the tray edge to create an
interference fit between the lid edge and the tray edge to secure
the lid to the tray.
19. The leak-resistant pulp container of claim 16, wherein the lid
edge is configured so that the outer wall of the lock portion
applies force to the outer portion of the tray edge to force the
seal portion of the tray edge against the seal portion of the lid
edge.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a U.S. national stage of application No.
PCT/US2014/028541, filed on 14 Mar. 2014, which claims the benefit
of U.S. Provisional Patent Application No. 61/799,008, filed on 15
Mar. 2013, both of which are hereby incorporated by reference in
their entireties.
FIELD OF THE INVENTION
[0002] The disclosed embodiments relate to resealable containers
with leak-resistant features for storing food, liquids, and various
other items. In particular, the disclosed embodiments relate to
resealable leak-resistant containers having a molded pulp tray with
a plastic lid.
BACKGROUND OF THE INVENTION
[0003] The use of plastic disposable containers and trays for
packaging, distributing, food are widespread in the marketplace.
There is a need for containers that are easy open and close, but at
the same time, resist leaks. This is especially true for containers
designed for liquids, e.g., soup containers. The leak-resistance
must be maintained even when the container is accidentally tilted
during transportation and handling so that the liquid contained
therein reaches the seam where the bottom (i.e., tray) and lid of
the container are joined.
[0004] Containers having a tray formed of molded pulp are often
seen as an environmentally-friendly option. However, the physical
properties of pulp material and its production processes can make
it difficult to produce a pulp container with leak-resistant
properties.
[0005] For example, it can be difficult to manufacture a pulp
container with a small "draft angle," which is the angle of the
upper edge of the container wall relative to vertical. Due to the
nature of the manufacturing processes of pulp containers, small
draft angles can create an array of production and quality
problems, such as uneven distribution of fibers in the produced
part, inconsistent part geometry, damage to manufacturing
equipment, etc. A typical paper container, on the other hand, such
as a soup cup, may have a draft angle of between 5 and 7 degrees.
This relatively small draft angle allows the container wall to
exert a greater force on the lid when it is wedged into the upper
portion of the container wall to seal the container, i.e., because
the force exerted by the container wall is largely in a horizontal
direction. This helps maintain a tighter seal for the paper
container. Similarly, plastic containers may be formed with an
equally small draft angle relatively easily.
[0006] A container having a small draft angle is difficult to
achieve in a molded pulp process, because a larger, i.e., wider,
draft angle typically must be used with pulp materials due to the
nature of the pulp molding process. The use of a wider draft angle
results in a greater portion of the force exerted by the container
walls on the lid being directed in a vertical direction of the
container when upright, i.e., a direction which tends to produce an
upward force on the lid. Therefore, a conventional pulp container
can be harder to seal in a leak-resistant manner.
[0007] Another physical property of pulp material which can make a
leak-resistant container difficult to manufacture is the relative
lack of flexibility of molded pulp. The lack of flexibility arises
from the characteristics of the natural fibers, which tend not to
stretch very much on their own or when molded together. This lack
of flexibility means that certain geometries, known as "undercuts,"
cannot easily be used in pulp containers. An undercut is a portion,
e.g., an edge portion, of a container which decreases in width as
the sidewall of the container extends toward its upper edge. In a
container lacking undercuts, on the other hand, the width of the
container increases continuously as the sidewall extends toward its
upper edge. An undercut can be achievable and useful in creating an
interconnection between a container tray and lid, such as in a
container made entirely of flexible materials, such as plastic.
However, a pulp container part having undercuts will likely tear as
it is removed from the mold due to its lack of flexibility and also
due to inherent texture characteristics of the pulp arising from
its manufacturing process. This characteristic effectively limits
the geometries which can be used in a pulp container and makes it
more difficult to achieve a leak-resistant design.
SUMMARY OF THE INVENTION
[0008] The disclosed embodiments provide leak-resistant, resealable
containers, e.g., for food products. The disclosed embodiments
include containers designed for liquids, e.g., soup containers, and
the like. The leak-resistance is maintained even when the container
is tilted so that the liquid contained therein reaches the seam
where the bottom (i.e., tray) and lid of the container are
joined.
[0009] The disclosed embodiments also provide various shapes of the
lid and tray rims which form locking mechanisms to keep the lid
attached to the bottom portion of the container.
[0010] In one aspect, the present invention provides a
leak-resistant pulp container with a plastic lid, including a tray
formed of molded pulp and having a bottom and a sidewall forming an
interior volume. The tray has an edge extending peripherally
outward from an upper edge of the sidewall, and the tray edge
having an outer portion. The container further includes a plastic
lid having an edge extending peripherally outward therefrom, and
the lid edge having an outer portion. The lid edge and the tray
edge each has a corresponding peripheral channel configured so that
one of the peripheral channels is received in the other of the
peripheral channels to secure the lid to the tray, each of the
peripheral channels comprising an inner wall and an outer wall
joined by a horizontal channel wall. The outer wall of the
peripheral channel of the lid edge has a protrusion which mates
with the outer portion of the tray edge to create an interference
fit between the lid edge and the tray edge to secure the lid to the
tray.
[0011] Embodiments of the present invention may include one or more
of the following features.
[0012] The inner wall of the peripheral channel of the tray edge
may have a sealing surface which presses against a corresponding
sealing surface of the inner wall of the peripheral channel of the
lid edge when the lid is secured to the tray, thereby forming a
leak-resistant seal between the lid edge and the tray edge. The lid
edge may be configured so that the outer wall of the peripheral
channel of the lid edge applies force to the outer portion of the
tray edge to force the sealing surface of the tray edge against the
sealing surface of the lid edge. The sealing surfaces of the lid
edge and the tray edge may extend to include at least a portion of
the horizontal channel walls of the lid edge and the tray edge. The
inner wall of the peripheral channel of the lid edge and the inner
wall of the peripheral channel of the tray edge may be dimensioned
to at least partially overlap in a cross-sectional plane, thereby
forcing the sealing surface of the tray edge against the sealing
surface of the lid edge when the lid is secured to the tray.
[0013] The protrusion of the outer wall of the peripheral channel
of the lid edge may have a lower lip which extends inward to keep
the outer portion of the tray edge in place in the protrusion,
thereby acting to secure the lid to the tray. The lower lip of the
protrusion of the outer wall of the peripheral channel of the lid
edge may be formed in separate peripheral segments around the
periphery of the lid.
[0014] The inner wall of the peripheral channel of the tray edge
may form a draft angle with respect to a vertical direction of the
container, when upright, of between about 8 degrees and about 12
degrees. The draft angle of the inner wall of the peripheral
channel of the tray edge may be between about 10 degrees and about
12 degrees.
[0015] The outer portion of the tray edge may be substantially flat
in a horizontal plane of the container when upright. A tab may
extend from the lid edge and beyond the tray edge. The tray and the
lid each may have a substantially oval shape.
[0016] The lid may be formed of any of the following plastic
materials: high density polyethylene (HDPE), polyethylene
terephthalate (PET), polypropylene (PP), polystyrene (PS), and
polylactic acid (PLA). The lid may be formed by a thermoforming
process. The lid may be formed by an injection molding process.
[0017] In another aspect, the present invention provides a
leak-resistant pulp container with a plastic lid, including a tray
formed of molded pulp and having a bottom and a sidewall forming an
interior volume. The tray has an edge extending peripherally
outward from an upper edge of the sidewall, the tray edge having an
outer portion. The container further includes a plastic lid having
an edge extending peripherally outward therefrom, the lid edge
having an outer portion. The lid edge and the tray edge each has a
corresponding lock portion configured so that one of the lock
portions mates with the other of the lock portions to secure the
lid to the tray. The lid edge and the tray edge each has a
corresponding seal portion configured so that one of the seal
portions presses against the other of the seal portions when the
lid is secured to the tray, thereby forming a leak-resistant seal
between the lid edge and the tray edge.
[0018] Embodiments of the present invention may include one or more
of the following features.
[0019] The seal portions of the lid edge and the tray edge may be
formed in an inner portion of the lid edge and the tray edge with
respect to the lock portions of the lid edge and the tray edge. The
lock portion of the lid edge may include an outer wall having a
protrusion which mates with the outer portion of the tray edge to
create an interference fit between the lid edge and the tray edge
to secure the lid to the tray. The lid edge may be configured so
that the outer wall of the lock portion applies force to the outer
portion of the tray edge to force the seal portion of the tray edge
against the seal portion of the lid edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above and/or other aspects and advantages will become
more apparent and more readily appreciated from the following
detailed description of the disclosed embodiments taken in
conjunction with the accompanying drawings of which:
[0021] FIG. 1 shows a perspective view of an embodiment of a
resealable leak-resistant container having a molded pulp tray with
a plastic lid.
[0022] FIG. 2 shows a perspective view of the molded pulp tray of
the container of FIG. 1.
[0023] FIG. 3 shows a top plan view of the container of FIG. 1.
[0024] FIG. 4 shows a top plan view of a resealable leak-resistant
container having a square shape.
[0025] FIG. 5 shows a top plan view of a resealable leak-resistant
container having a round shape.
[0026] FIG. 6 shows a vertical cross-sectional view of the
container of FIG. 1 taken along line A-A depicted in FIG. 3.
[0027] FIG. 7 shows an enlargement of Region B of FIG. 6 showing
the peripheral edge of the lid interlocking with the peripheral
edge of the tray.
[0028] FIG. 8 shows a theoretical view of the enlargement of Region
B of FIG. 6 showing the dimensional overlap of the peripheral edge
of the lid and the peripheral edge of the tray, as designed.
DETAILED DESCRIPTION
[0029] FIGS. 1-3 show an embodiment of a resealable leak-resistant
container 100 having a molded pulp tray 110 with a plastic lid 120.
The tray 110 has a bottom 115 and a sidewall 117 forming an
interior volume (see, e.g., FIG. 2). The tray 110 has an edge 125
extending peripherally outward from an upper edge of the sidewall
117. The tray 110 and the lid 120 each has a substantially oval
shape (see, e.g., FIG. 3). Although, other shapes are also
possible, such as square (see FIG. 4) or round (see FIG. 5). A tab
135 may extend from the lid edge 130 and beyond the tray edge 125.
The inward facing lip portions 185 are described below in the
discussion of FIG. 7.
[0030] The lid 120 of the leak-resistant pulp container 100 may be
formed of any of the following plastic materials: high density
polyethylene (HDPE), polyethylene terephthalate (PET),
polypropylene (PP), polystyrene (PS), and polylactic acid (PLA).
The plastic lid can be formed by various processes, including, for
example, thermoforming and injection molding.
[0031] The tray 110 of the leak-resistant pulp container 100 is
formed of pulp which has undergone a pressing and molding process.
The pulp may be formed of various fibrous materials, such as, for
example, Bagasse, bamboo, wheat straw, wood, etc. The pulp is
processed by pouring a suspension of pulp material and liquid
(e.g., water) into a mold having a cavity with a number of holes
and which is covered with a very fine mesh. The liquid is suctioned
away, and the collected fibers on the mesh are pressed between two
corresponding heated molds to squeeze out additional liquid. In
further steps, additional pressing and heat processes may be
applied to form and dry the final parts.
[0032] FIG. 6 shows a vertical cross-sectional view of the
container 100 of FIG. 1 (when upright) taken along line A-A
depicted in FIG. 3. It can be seen in this view that the lid edge
130 and the tray edge 125 each has a corresponding peripheral
channel 140 configured so that one of the peripheral channels is
received in the other of the peripheral channels to secure the lid
120 to the tray 110. In the embodiment depicted, the peripheral
channel 140 of the tray edge 125 is received into the peripheral
channel 140 of the lid edge 130.
[0033] FIG. 7 shows an enlargement of Region B of FIG. 6 showing
the peripheral edge of the lid 130 interlocking with the peripheral
edge of the tray 125. The peripheral channel 140 of the lid edge
130 has an inner wall 145 and an outer wall 150 joined by a
horizontal channel wall 155. Similarly, the peripheral channel 140
of the tray edge 125 has an inner wall 160 and an outer wall 165
joined by a horizontal channel wall 170. In the embodiment
depicted, the tray edge 125 has an outer portion 180 which is
substantially flat in a horizontal plane of the container 100. The
plastic lid 120 also has an edge extending peripherally outward
therefrom which has a substantially flat outer portion 182.
[0034] The outer wall 150 of the peripheral channel 140 of the lid
edge 130 has a protrusion 175 which mates with the outer portion
180 of the tray edge 125 to create an interference fit between the
lid edge 130 and the tray edge 125 to secure the lid 120 to the
tray 110. The inner wall 160 of the peripheral channel 140 of the
tray edge 125 has a sealing surface 162 which presses against a
corresponding sealing surface 147 of the inner wall 145 of the
peripheral channel 140 of the lid edge 130 when the lid 120 is
secured to the tray 110, thereby forming a leak-resistant seal
between the lid edge 130 and the tray edge 125. The sealing
surfaces (147, 162) of the lid edge 130 and the tray edge 125 may
extend to include at least a portion of the horizontal channel
walls (155, 170) of the lid edge 130 and the tray edge 125.
[0035] The inner wall 160 of the peripheral channel 140 of the tray
edge 125 may form a draft angle with respect to a vertical
direction of the container (when upright) of between about 8
degrees and about 12 degrees, or between about 10 degrees and about
12 degrees. In the embodiment depicted, the draft angle is about 12
degrees. The draft angle of the inner wall 162 of the lid edge 130
is substantially equal to that of the inner wall 160 of the tray
edge 125 in order to achieve a strong seal.
[0036] The protrusion 175 of the outer wall 150 of the peripheral
channel 140 of the lid edge 130 has a lower lip 185 which extends
inward to keep the outer portion 180 of the tray edge 125 in place
in the protrusion 175, thereby acting to secure the lid 120 to the
tray 110. The lower lip 185 may be formed continuously around the
periphery of the lid 120 or in separate peripheral segments (see,
e.g., FIG. 1).
[0037] FIG. 8 shows a theoretical view of the enlargement of Region
B of FIG. 6 showing the dimensional overlap, i.e., interference
fit, of the peripheral edge of the lid 130 and the peripheral edge
of the tray 125, as designed. The inner wall 145 of the peripheral
channel 140 of the lid edge 130 and the inner wall 160 of the
peripheral channel 140 of the tray edge 125 are dimensioned to at
least partially overlap in a cross-sectional plane. This, in turn,
helps force the sealing surface 162 of the tray edge 125 against
the sealing surface 147 of the lid edge 130 when the lid 120 is
secured to the tray 110. The view depicted is theoretical, in the
sense that the dimensionally-overlapping portions will actually
deform slightly and abut each other when the container is
closed.
[0038] In addition, the lid edge 130 may be configured so that the
outer wall 150 of the peripheral channel 140 of the lid edge 130,
and in particular the protrusion 175 formed therein, applies force
to the outer portion 180 of the tray edge 125 to force the sealing
surface 162 of the tray edge 125 against the sealing surface 147 of
the lid edge 130. This may be done by dimensioning the outer
portion 180 of the tray edge 125 so that it has dimensional
overlap, i.e., an interference fit, with the protrusion 175, as
shown in FIG. 8.
[0039] Although example embodiments have been shown and described
in this specification and figures, it would be appreciated by those
skilled in the art that changes may be made to the illustrated
and/or described example embodiments without departing from their
principles and spirit.
* * * * *