U.S. patent application number 14/940645 was filed with the patent office on 2016-05-19 for method of forming a package.
The applicant listed for this patent is Berry Plastics Corporation. Invention is credited to Ken Jochem, Jeffrey C Minnette.
Application Number | 20160137321 14/940645 |
Document ID | / |
Family ID | 55961019 |
Filed Date | 2016-05-19 |
United States Patent
Application |
20160137321 |
Kind Code |
A1 |
Minnette; Jeffrey C ; et
al. |
May 19, 2016 |
METHOD OF FORMING A PACKAGE
Abstract
A package includes a container formed to include an open mouth
arranged to open into an interior product-storage region and a
closure arranged to close the open mouth when the closure is
coupled to the container.
Inventors: |
Minnette; Jeffrey C;
(Evansville, IN) ; Jochem; Ken; (Mt. Vernon,
IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Berry Plastics Corporation |
Evansville |
IN |
US |
|
|
Family ID: |
55961019 |
Appl. No.: |
14/940645 |
Filed: |
November 13, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62079131 |
Nov 13, 2014 |
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Current U.S.
Class: |
53/421 |
Current CPC
Class: |
B65B 3/04 20130101; B65B
55/24 20130101; B65B 7/168 20130101; B65B 7/2878 20130101; B65D
77/2088 20130101 |
International
Class: |
B65B 7/28 20060101
B65B007/28 |
Claims
1. A process for forming a sealed package comprising the steps of
providing an open vessel including a container formed to include a
mouth arranged to open into an interior product-storage region of
the container and a sheet-support ring, providing a membrane sheet
including a center portion, an outer seal band located in
spaced-apart relation to the center portion and arranged to extend
around and surround the center portion, and an inner seal band
located between the outer seal band and the center portion and
arranged to extend around and surround the center portion, locating
the membrane sheet relative to the open vessel to cause the center
portion to overlie the mouth, the inner seal band to overlie and
align with an upwardly facing surface of the brim, and the outer
seal band to overlie and align with an outer surface of the
sheet-support ring, coupling the outer seal band to the outer
surface of the sheet-support ring to form a permanent bond between
the outer seal band and the sheet-support ring, and coupling the
inner seal band to the upwardly facing surface of the brim to
establish a temporary bond between the inner seal band and the
upwardly facing surface of the brim to establish a sealed
package.
2. The process of claim 1, further comprising the step of filling
the open vessel with products through the mouth into the interior
product-storage region after the providing the open vessel
step.
3. The process of claim 2, further comprising the step of cleaning
the upwardly facing surface of the brim of any spilled products
located on the upwardly facing surface of the brim during the
filling step.
4. The process of claim 3, wherein the locating step occurs after
the providing the membrane sheet step and the providing the open
vessel step.
5. The process of claim 4, wherein the cleaning step occurs after
the coupling the outer seal band step.
6. The process of claim 5, wherein the cleaning step includes the
steps of moving the sheet-support ring in a downward direction
relative to the brim of the container and stretching the membrane
sheet to cause any spilled food product trapped between the
membrane sheet and the brim of the container to be wiped off the
upwardly facing surface of the brim.
7. The process of claim 1, wherein the coupling the inner seal band
step occurs after the coupling the outer seal band step.
8. The process of claim 7, wherein the providing the membrane sheet
step is performed after the providing the open vessel step.
9. The process of claim 8, further comprising the step of filling
the open vessel with products through the mouth into the interior
product-storage region after the providing the open vessel
step.
10. The process of claim 9, further comprising the step of cleaning
the upwardly facing surface of the brim of any spilled products
located on the upwardly facing surface of the brim during the
filling step.
11. The process of claim 10, wherein the locating step occurs after
the providing the membrane sheet step and the providing the open
vessel step and the cleaning step occurs after the coupling the
outer seal band step.
12. The process of claim 11, wherein the cleaning step includes the
steps of moving the sheet-support ring in a downward direction
relative to the brim of the container and stretching the membrane
sheet to cause any spilled food product trapped between the
membrane sheet and the brim of the container to be wiped off the
upwardly facing surface of the brim.
13. The process of claim 1, wherein the providing the open vessel
step includes the steps of providing the container, providing the
sheet-support ring, and coupling the sheet-support ring to the
container to establish the open vessel.
14. The process of claim 13, wherein the sheet-support ring mates
temporarily in snapping relation with a portion of the brim.
15. The process of claim 14, wherein the locating step occurs after
the coupling the sheet-support ring step.
16. A process for forming a sealed package comprising the steps of
providing an open vessel including a container formed to include a
mouth arranged to open into an interior product-storage region of
the container and a sheet-support ring coupled to a brim of the
container, providing a membrane sheet including a center portion,
an outer seal band located in spaced-apart relation to the center
portion, and an inner seal band located between the outer seal band
and the center portion, locating the membrane sheet relative to the
open vessel to cause the inner seal band to overlie and align with
a portion of the container, and the outer seal band to overlie and
align with a portion of the sheet-support ring, coupling the outer
seal band to the portion of the sheet-support ring to form a
permanent bond between the outer seal band and the sheet-support
ring, and coupling the inner seal band to the portion of the
container to establish a temporary bond between the inner seal band
and the container to establish a sealed package.
17. The process of claim 16, further comprising the steps of
filling the open vessel with products through the mouth into the
interior product-storage region after the providing the open vessel
step and before the locating step and cleaning an upwardly facing
surface of the brim of any spilled products located on the upwardly
facing surface of the brim during the filling step.
18. The process of claim 17, wherein the cleaning step occurs after
the coupling the outer seal band step.
19. A process for forming a sealed package comprising the steps of
providing an open vessel including a container formed to include a
mouth arranged to open into an interior product-storage region of
the container and a sheet-support ring coupled to a brim of the
container, providing a membrane sheet including a center portion,
an outer seal band located in spaced-apart relation to the center
portion and arranged to extend around and surround the center
portion, and an inner seal band located between the outer seal band
and the center portion and arranged to extend around and surround
the center portion, filling the open vessel with products through
the mouth into the interior product-storage region, locating the
membrane sheet relative to the open vessel to cause the center
portion to overlie the mouth, the inner seal band to overlie and
align with an upwardly facing surface of the brim, and the outer
seal band to overlie and align with an outer surface of the
sheet-support ring, coupling the outer seal band to the outer
surface of the sheet-support ring to form a permanent bond between
the outer seal band and the sheet-support ring after the locating
step, cleaning the upwardly facing surface of the brim of any
spilled products located on the upwardly facing surface of the brim
during the filling step after the coupling the outer seal band
step, and coupling the inner seal band to the upwardly facing
surface of the brim to establish a temporary bond between the inner
seal band and the upwardly facing surface of the brim after the
cleaning step to establish a sealed package.
20. The process of claim 19, wherein the cleaning step includes the
steps of moving the sheet-support ring in a downward direction
relative to the brim of the container and stretching the inner seal
band of the membrane sheet to cause any spilled food product
trapped between the membrane sheet and the brim of the container to
be wiped off the upwardly facing surface of the brim.
Description
PRIORITY CLAIM
[0001] This application claims priority under 35 U.S.C.
.sctn.119(e) to U.S. Provisional Application Ser. No. 62/079,131,
filed Nov. 13, 2014, which is expressly incorporated by reference
herein.
BACKGROUND
[0002] The present disclosure relates to package, and particularly
to a package including a container and a closure for the container.
More particularly, the present disclosure relates to a method of
forming a package.
SUMMARY
[0003] According to the present disclosure, a package includes a
container formed to include an open mouth arranged to open into an
interior product-storage region and a closure arranged to close the
open mouth when the closure is coupled to the container.
[0004] In illustrative embodiments, a package is formed using a
package-forming process. The package-forming process begins with
providing an open vessel including a container and a sheet-support
ring coupled to a brim of the container. The open vessel is then
filled with food products. A package is established when a membrane
sheet is coupled permanently to the sheet-support ring and
temporarily to the brim of the container after the container has
been filled.
[0005] Additional features of the present disclosure will become
apparent to those skilled in the art upon consideration of
illustrative embodiments exemplifying the best mode of carrying out
the disclosure as presently perceived.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0006] The detailed description particularly refers to the
accompanying figures in which:
[0007] FIG. 1 is a perspective view of a sealed packaged in
accordance with the present disclosure showing that the sealed
package includes a container formed to include an interior
product-storage region therein and a closure coupled to the
container to close an open mouth formed in the container and
arranged to open into the interior product-storage region;
[0008] FIG. 2 is an exploded assembly view and diagrammatic view of
the package of FIG. 1 showing that the package includes, from top
to bottom, the container including an upwardly facing brim, a
sheet-support ring, and a membrane sheet and suggesting that the a
sealing head including an outer sealing ring and an inner sealing
ring is used in the factory to couple an outer seal band included
in the membrane sheet to the sheet-support ring and an inner seal
band included in the membrane sheet to the upwardly facing brim of
the container to establish the sealed package of FIG. 1;
[0009] FIG. 3 is a plan view and diagrammatic view of the membrane
sheet of FIGS. 1 and 2 showing that the membrane sheet includes,
from inside to outside, a center portion arranged to close the open
mouth formed in the container when the membrane sheet is coupled to
the sheet-support ring, the inner seal band configured to couple
temporarily to the upwardly facing brim included in the container,
and the outer seal band configured to couple permanently to the
sheet-support ring;
[0010] FIG. 4 is a partial perspective view of an open vessel
included in the package of FIGS. 1 and 2 showing that the open
vessel includes the container and the sheet-support ring and that
the sheet-support ring is coupled to the container prior to
coupling the membrane sheet to both the sheet-support ring and the
container;
[0011] FIG. 5 is a diagrammatic view of a package-forming process
in accordance with the present disclosure showing that the process
includes the steps of providing an open vessel as shown in FIG. 4,
providing a membrane sheet as shown in FIG. 3, filling the open
vessel in a factory, locating the center portion of the membrane
sheet over the mouth of the container, the inner seal band over the
upwardly facing brim, and the outer seal band over the
sheet-support ring, coupling the outer seal band to the
sheet-support ring using the sealing head, optionally cleaning the
upwardly facing brim of the container, and coupling the inner seal
band to the upwardly facing brim using the sealing head to
establish the sealed package of FIG. 1;
[0012] FIG. 5A is a diagrammatic view of the providing the open
vessel step showing that the step includes the steps of providing
the container, providing the sheet-support ring, and mating the
sheet support ring mates temporarily in snapping relation with the
brim of the container to establish the open vessel;
[0013] FIG. 6 is a perspective view of a pair of open vessels
showing a first open vessel being inserted through a mouth of a
second open vessel into the product-storage region of the second
open vessel to establish a stack of open vessels as suggested in
FIG. 7
[0014] FIG. 7 is a perspective view of a stack of open vessels
showing that the stack of open vessels minimizes an amount of
storage spaced needed to store multiple open vessels prior to
filling in the factory;
[0015] FIG. 8 is a sectional view taken along line 8-8 of FIG. 1;
and
[0016] FIG. 9 is an enlarged portion taken from the circled region
of FIG. 8 showing the membrane sheet coupled to the sheet-support
ring and the upwardly facing brim of the container.
DETAILED DESCRIPTION
[0017] A sealed package 10 in accordance with the present
disclosure is shown in FIG. 1. Sealed package 10 is formed
according to a package-forming process 100 as shown in FIG. 5.
Package-forming process 100 uses an open vessel 12 including a
container 14 and a sheet-support ring 16 coupled to the container
14 and a membrane sheet 18 to establish sealed package 10. Open
vessel 12 is filled with products, and then, membrane sheet 18 is
coupled by a sealing head 20 to sheet-support ring 16 and container
14 to establish sealed package 10.
[0018] Package 10 includes membrane sheet 18, sheet-support ring
16, and container 14 as shown in FIG. 2. Prior to sealing,
sheet-support ring 16 is coupled to container 14 to establish open
vessel 12 and membrane sheet 18 is separate from open vessel 12.
After sealing, sheet-support ring 16 and membrane sheet 18
cooperate to establish a closure 22 which is coupled to container
14 by a temporary bond 18T between membrane sheet 18 and container
14 and a permanent bond 18P between membrane sheet 18 and
sheet-support ring 16.
[0019] Container 14 includes a bowl 24 and an upwardly facing brim
26 as shown, for example, in FIG. 2. Bowl 24 is formed to include
an interior product-storage region 28 therein. Upwardly facing brim
26 defines an open mouth 30 arranged to open into interior
product-storage region 28. Upwardly facing brim 26 includes an
upper surface 26S which is configured to mate with membrane sheet
18 and form temporary bond 18T as suggested in FIG. 9. U.S. Pat.
App. Pub. No. 2013/0092759 published on Apr. 18, 2013, U.S. Pat.
App. Pub. No. 2012/0211497 published on Aug. 23, 2012, U.S. Pat.
App. Pub. No. 2013/0047559 published on Feb. 28, 2013, U.S. Pat.
App. Pub. No. 2014/0215974 published on Aug. 7, 2014, U.S. Pat.
App. Pub. No. 2013/0104505 published on May 2, 2013, U.S. Pat. App.
Pub. No. 2014/0326735 published on Nov. 6, 2014, U.S. Pat. App.
Pub. No. 2015/0203263 published Jul. 23, 2015, and U.S. patent
application Ser. No. 14/882,263 filed Oct. 13, 2015 are hereby
incorporated by reference in their entirety for disclosure relating
to containers.
[0020] Sheet-support ring 16 includes an outer surface 16S which is
configured to mate with membrane sheet 18 to form a permanent bond
18P therebetween as suggested in FIG. 9. In one example,
sheet-support ring 16 includes a lid-retention lug 34 configured to
engage temporarily in snapping relation with a portion of brim 26.
Lid-retention lug 34 is located in spaced-apart relation to a lower
end 36 of sheet-support ring 16 and be located between upper
surface 26S and lower end 36. U.S. Pat. App. Pub. No. 2013/0092759
published on Apr. 18, 2013, U.S. Pat. App. Pub. No. 2012/0211497
published on Aug. 23, 2012, U.S. Pat. App. Pub. No. 2013/0047559
published on Feb. 28, 2013, U.S. Pat. App. Pub. No. 2014/0326735
published on Nov. 6, 2014, U.S. Pat. App. Pub. No. 2015/0203263
published Jul. 23, 2015, and U.S. patent application Ser. No.
14/882,263 filed Oct. 13, 2015 are hereby incorporated by reference
in their entirety for disclosure relating to sheet-support
rings.
[0021] Membrane sheet 18 includes a center portion 18A, an inner
seal band 18B, and an outer seal band 18C as shown in FIGS. 3 and
9. Center portion 18A is arranged to close open mouth 30 when
membrane sheet 18 is coupled to sheet-support ring 16 and upwardly
facing brim 26. Inner seal band 18B is configured to couple
temporarily to upper surface 26S of upwardly facing brim 26
included in container 14. Outer seal band 18C is configured to
couple permanently to outer surface 16S of sheet-support ring 16 as
shown in FIG. 9. U.S. Pat. App. Pub. No. 2013/0092759 published on
Apr. 18, 2013, U.S. Pat. App. Pub. No. 2012/0211497 published on
Aug. 23, 2012, U.S. Pat. App. Pub. No. 2013/0047559 published on
Feb. 28, 2013, U.S. Pat. App. Pub. No. 2014/0215974 published on
Aug. 7, 2014, U.S. Pat. App. Pub. No. 2013/0104505 published on May
2, 2013, U.S. Pat. App. Pub. No. 2014/0326735 published on Nov. 6,
2014, U.S. Pat. App. Pub. No. 2015/0203263 published Jul. 23, 2015,
and U.S. patent application Ser. No. 14/882,263 filed Oct. 13, 2015
are hereby incorporated by reference in their entirety for
disclosure relating to membrane sheets and coupling of membrane
sheets to sheet-support rings.
[0022] In one example, outer surface 16S of sheet-support ring 16
is arranged to extend downwardly away from inner seal band 18B of
membrane sheet 18. Downwardly extending outer seal surface 16S
minimizes shear stress experienced by outer seal band 18C during
separation of closure 22 from container 14 the first time. During
removal of closure 22 from container 14 the first time, temporary
bond 18T resists upward movement of closure 22. As temporary bond
18T is overcome, temporary bond 18T exerts a force on permanent
bond 18P. Downwardly extending outer seal surface 16S causes a
substantial portion of the force to be transferred to sheet-support
ring 16 in the form of compressive forces rather than as a shearing
force. As a result, temporary bond 18P is maintained and damage to
outer seal band 18C at permanent bond 18P is minimized.
[0023] In one illustrative example, membrane sheet 18 is made from
a polyolefin material. Polyolefin materials include polypropylene,
polyethylene, blends thereof, or any other suitable alternative.
Membrane sheet 18 may also be made from a multi-layer film. One or
more of the layers may be an oxygen barrier and a tie layer. The
oxygen barrier, for example, may be ethylene vinyl alcohol (EVOH)
or any other suitable alternative. Container 14 and sheet-support
16 are also made from polyolefin materials including, for example,
polypropylene, polyethylene, blends thereof, or any other suitable
alternative. As a result of both membrane sheet 18, container 14,
and sheet-support ring 16 being formed from polyolefin, permanent
bond 18P and temporary bond 18T may be chemical bonds established
as a result of applying heat which causes melting and intermingling
of the polyolefin materials of each.
[0024] Sealed package 10 is formed by package-forming process 100
as shown in FIG. 5. Package-forming process 100 begins with a
providing operation 102 in which open vessel 12 is provided.
Package-forming process 100 also includes a providing operation 104
in which membrane sheet 18 is provided. In one example, membrane
sheet 18 may be provided as a separate membrane sheet. In another
example, membrane sheet 18 may be included in a carrier sheet that
includes other membrane sheets and scrap material.
[0025] Providing operation 102 includes the operations of providing
102A container 14, providing 102B sheet-support ring 16, and
coupling 102C sheet-support ring to container 14 to establish open
vessel 12 as shown in FIG. 5A. In one example, sheet-support ring
14 mates temporarily in snapping relation with a portion of brim 26
during coupling operation 102C. In one example, providing operation
102 may occur in a different facility from providing operation 104
and coupling operation 106 or in the same facility. In one example,
container 14 is formed in a thermoforming process during providing
operation 102A.
[0026] After providing operations 102, 104 are complete,
package-forming process 100 proceeds to a filling operation 106 as
shown in FIG. 5. During filling operation 106, food products or
other items are placed in interior product-storage region 28 formed
in container 14 through open mouth 30 formed in container 14. In
some instances, portions of food products may be dropped on upper
surface 26S of upwardly facing brim 26 included in container
14.
[0027] Package-forming process 100 then proceeds to a locating
operation 108 as shown in FIG. 5. During locating operation 108,
membrane sheet 18 is located above open vessel 12 after filling
operation 106 is complete. Locating operation 108 causes membrane
sheet 18 to be located such that sealing head 20 causes membrane
sheet 18 to be coupled to both upwardly facing brim 26 and
sheet-support ring 16. During the locating operation, membrane
sheet 18 may be located relative to open vessel 12 either
individually or as part of the carrier sheet with scrap and other
membrane sheets.
[0028] Package-forming process 100 then proceeds to a coupling
operation 110 as shown in FIG. 5. During coupling operation 110,
outer seal band 18C of membrane sheet 18 is coupled to outer
surface 16S of sheet-support ring 16 by permanent bond 18P. In one
example, permanent bond 18P is established by an outer sealing ring
20A included in sealing head 20. In one example, permanent bond 18P
is a heat seal established when outer sealing ring 20A provides
heat to outer seal band 18C and outer surface 16S of sheet-support
ring 20A. However, any other suitable alternatives and combinations
may be used to couple outer seal band 18C to outer surface 16S of
sheet-support ring 16.
[0029] Package-forming process 100 may include a cleaning operation
112 as shown in FIG. 5 in phantom. Cleaning operation 112 may be
used to remove spilled food products located on upper surface 26S
of upwardly facing brim 26. U.S. Pat. App. Pub. No. 2013/0047559
published on Feb. 28, 2013 and U.S. Pat. App. Pub. No. 2013/0104505
published on May 2, 2013 are hereby incorporated by reference in
their entirety for disclosure relating to wiping of brims.
Illustratively, cleaning operation 112 is facilitated by
sheet-support ring 16 being a separate component from container 14
which allows movement of sheet-support ring 16 relative to
container 14.
[0030] Package-forming process 100 proceeds to a coupling operation
114 as shown in FIG. 5. During coupling operation 114, inner seal
band 18B of membrane sheet 18 is coupled to upper surface 26S of
upwardly facing brim 26 by temporary bond 18T. Once membrane sheet
18 has been coupled to both sheet-support ring 16 and upwardly
facing brim 26, sealed package 10 is established. In one example,
temporary bond 18T is established by an inner sealing ring 20B
included in sealing head 20. In one example, temporary bond 18T is
a heat seal established when inner sealing ring 20B provides heat
to inner seal band 18B and upper surface 26S of upwardly facing
brim 26. However, any other suitable alternatives and combinations
may be used to couple inner seal band 18B to upper surface 26S of
upwardly facing brim 26. Inner sealing ring 20B is located a first
radial distance from a central axis 11 of container 14 while outer
sealing ring 20A is located a relatively greater second radial
distance from the central axis of container 14.
[0031] Open vessel 12 is configured to minimize an amount of spaced
used to store and transport container 14, sheet-support ring 16,
and membrane sheet 18. As shown in FIG. 6, two or more open vessels
12A and 12B may be arranged to establish a stack 32 of open
vessels. First open vessel 12A is arranged to extend through open
mouth 30B of second open vessel 12B and into interior
product-storage region of second open vessel 12B. Stack 32
minimizes space for storing containers 14A, 14B and sheet-support
rings 16A, 16B as a result of each sheet-support ring 16A, 16B
being coupled to each associated container 14A, 14B. Membrane sheet
18 may be stored and shipped as part of a rolled carrier sheet
including several membrane sheets and scrap.
[0032] In one example, membrane sheet 18 is separated from the
scrap and other membrane sheets by a cutting operation that may be
included in package-forming process 100. The cutting operation may
occur before, during, or after coupling operations 110, 114. The
cutting operation may be performed by sealing head 20 which may
include a cutter configured to separate membrane sheet 18 from the
carrier sheet.
[0033] While coupling operation 110 is shown preceding coupling
operation 114, it is within the scope of the present disclosure for
coupling operation 110 to follow coupling operation 114. It is also
within the scope of the present disclosure for coupling operations
110, 114 to occur about the same time.
* * * * *