MULTI WALL CONTAINER AND PACKAGE
United States Patent 3737093
The specification describes a multi-walled package of a nestable configuration that has an inner shell of thermoformed plastic material and an outer shell of paper cardboard material secured thereto and adapted to be printed thereon. The relationship of said shells being that the inner shell has a formed rim portion and a base portion each adapted to be self-sustaining or rigid, with a relatively thin flexible intermediary wall portion, and the outer shell is secured to the wall portion of the inner shell in a manner to provide structural rigidity to the wall portion and in turn the entire container. A closure having snap-in engagement with the container rim, at a number of positions is also provided.
US Patent References:
Drinking cup
Vogel - April 1954 - 2675954
Insulated nestable container and method of making the same
Anderson et al. - August 1965 - 3203611
Ornamental double-walled tumbler
Nalle, Jr. - May 1961 - 2984035
NESTABLE DOUBLE-WALLED DISPOSABLE CONTAINER
McDevitt - May 1971 - 3580468
Container
Birkland - December 1938 - 2139660
Drinking cup
Vogel - April 1954 - 2675954
Insulated nestable container and method of making the same
Anderson et al. - August 1965 - 3203611
Ornamental double-walled tumbler
Nalle, Jr. - May 1961 - 2984035
NESTABLE DOUBLE-WALLED DISPOSABLE CONTAINER
McDevitt - May 1971 - 3580468
Container
Birkland - December 1938 - 2139660
Inventors:
Amberg, Stephen W. (Saint James, NY)
Ludder, Rodney E. (Glen Head, NY)
Ludder, Rodney E. (Glen Head, NY)
Application Number:
05/162222
Publication Date:
06/05/1973
Filing Date:
07/13/1971
View Patent Images:
Export Citation:
Assignee:
Owens-Illinois, Inc. (Toledo, OH)
Primary Class:
Other Classes:
229/117.270, 220/793, 206/520, 229/400, 40/306, 220/62.200, 220/375, 220/62.140, 220/23.870, 206/459.500
International Classes:
B65D21/02; B65D25/34; B65D43/02; B65D55/06; B65D25/00; B65D55/02; B65D3/10
Field of Search:
40/306,308,310,312,324 220/9R,97C,97F,60 229/1.5B,14R,14BI,14BW,14H,43,45
US Patent References:
Primary Examiner:
Rothberg, Samuel B.
Assistant Examiner:
Lipman, Steven E.
Parent Case Data:
RELATED APPLICATIONS
This application is a continuation of our co-pending application Ser. No. 747,183, filed July 24, 1968, now abandoned.
Claims:
We claim
1. An externally decorated container, comprising
2. A container comprising
3. A container as in claim 1, wherein said outer shell has a layer of blocking material thereon forming a barrier for the transmission of ultraviolet rays therethrough.
4. A container as in claim 1, wherein said inner shell has in its wall portion a plurality of alternate extending ribs terminating in spaced apart edges.
5. A container as in claim 4, wherein said outer shell has an inner surface in closely fitting relationship to said inner shell wall portion such that the inner surface is in engagement with said spaced apart edges.
6. A container, comprising
7. A container package comprising
8. A package as in claim 7, wherein said depressions include an inclined portion substantially merging with said wall portion.
9. A package as in claim 8, wherein said closure means includes a substantially flat cover portion, a peripherally extending rim merging with the outer edge of said flat body, said rim including a substantially horizontal portion, and a downwardly extending outer wall, said rim containing said plurality of outwardly extending beads adapted to engage said depressions, said beads including an inclined portion, the relationship of said inclined portions of said respective beads and depressions providing the frictional interlocking relation therebetween.
10. A package as claimed in claim 9, wherein said rim includes an inner wall extending outwardly from said cover portion and angularly disposed thereto at an angle of said wall portion, the dimensional relationship of said inner wall and wall portion being such that an interference fit exists therebetween to provide a substantially air tight seal therebetween.
11. A container package comprising
12. A package as in claim 11, wherein said tab is adjacent one of said locking beads, and said locking bead adjacent said tab having a lesser degree of frictional interference than the remaining locking beads to facilitate the removal of said closure by means of said tab.
13. A package as in claim 11, wherein said removal means further includes a complimentary tab extending from said container in overlapping relationship with said closure tab.
14. A package as in claim 13, and further including means for joining said tabs together to provide a tamperproof package.
1. An externally decorated container, comprising
2. A container comprising
3. A container as in claim 1, wherein said outer shell has a layer of blocking material thereon forming a barrier for the transmission of ultraviolet rays therethrough.
4. A container as in claim 1, wherein said inner shell has in its wall portion a plurality of alternate extending ribs terminating in spaced apart edges.
5. A container as in claim 4, wherein said outer shell has an inner surface in closely fitting relationship to said inner shell wall portion such that the inner surface is in engagement with said spaced apart edges.
6. A container, comprising
7. A container package comprising
8. A package as in claim 7, wherein said depressions include an inclined portion substantially merging with said wall portion.
9. A package as in claim 8, wherein said closure means includes a substantially flat cover portion, a peripherally extending rim merging with the outer edge of said flat body, said rim including a substantially horizontal portion, and a downwardly extending outer wall, said rim containing said plurality of outwardly extending beads adapted to engage said depressions, said beads including an inclined portion, the relationship of said inclined portions of said respective beads and depressions providing the frictional interlocking relation therebetween.
10. A package as claimed in claim 9, wherein said rim includes an inner wall extending outwardly from said cover portion and angularly disposed thereto at an angle of said wall portion, the dimensional relationship of said inner wall and wall portion being such that an interference fit exists therebetween to provide a substantially air tight seal therebetween.
11. A container package comprising
12. A package as in claim 11, wherein said tab is adjacent one of said locking beads, and said locking bead adjacent said tab having a lesser degree of frictional interference than the remaining locking beads to facilitate the removal of said closure by means of said tab.
13. A package as in claim 11, wherein said removal means further includes a complimentary tab extending from said container in overlapping relationship with said closure tab.
14. A package as in claim 13, and further including means for joining said tabs together to provide a tamperproof package.
Description:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to multi-walled packages in general and particularly to multi-walled containers of the type adapted to be nested one within the other, said outer shell construction joined together in a manner in which the structural rigidity of the containers are provided by a novel coupling of interrelated portions of the inner and outer shells.
In the packaging industry today there exists for a number of products such as potato chips and related snack foods, flexible bag packages. These packages range in weight from a fraction of an ounce to over two pounds. The materials used for the manufacturer of such bags are generally of a cellophane-polypropylene laminate. The present packages are such that they cannot easily be stacked on the shelf, they have difficulty in packaging them for shipment and they consume considerable space, that could be more economically occupied. With these difficulties in mind, applicants set out to provide a rigid container that would provide a sufficiently long shelf life to the product packaged therein, one having distinctive configuration for good merchandising appeal, with utilization of storage capacity and a suitable surface on the package and closure for graphic display.
Although the principles of the present invention are broadly applicable to packages, including receptacles, containers and cups, for comestibles of various forms, solids, fluids both hot and cold, the present invention is particularly adapted for use in conjunction with food packaging containers, providing storage of comestibles therein and hence it has been generally so illustrated and will be so described.
2. DESCRIPTION OF THE PRIOR ART
Heretofore, a number of packages have been proposed that have dealt broadly with the use of multiple layers to form the walls thereof and may be generally defined as double walled or multi-wall containers. The construction of these containers have generally fallen into two basic areas.
The first area, deals with insulated containers, that are adapted primarily to be used as a drinking vessel, and which may be manufactured out of a high density plastic material such as polystyrene or, in turn, out of a foamed polystyrene material that is generally bonded to another material which may be paper or plastic. Examples of insulated containers of this nature are disclosed, for example, in U.S. Pat. Nos. 3,079,027; 3,049,277; 2,853,222 and RE 25,618, and others which are well-known in the art.
Essentially, this group of patents is directed to providing an insulated container to be used as a drinking vessel in which the comestible contained therein may be retained at the proper elevated temperature. The construction of these containers is essentially one in which we have a substantially structurally rigid inner shell portion, that has secured thereto an outer shell portion and the insulating characteristics of the container are obtained by having either the inner and outer shells in spaced relationship to each other, or forming one or both of the shells of a plastic insulative material such as foam polystyrene or an equivalent. This type of construction is essentially not related to the present invention in that both shells are structurally rigid and not interdependent on each other for strength.
The second area, in contrast to the above, which is disclosed in a number of prior patents, generally relates to containers in which we have a structurally rigid exterior shell and in which the interior surface is essentially formed of a very thin, flexible sheet material, which has not a permanent configuration or structural rigidity and relies entirely on the outer shell to provide the requisite form of the container. For example, in the U.S. Pat. No. 3,150,811, we have a container in which we have an inner liner that is of a resilient plastic material adhered to the interior of the container.
U.S. Pat. No. 3,355,080, also discloses a container which is of essentially similar construction in that there is a tubular inner-shell, and as stated in the patent, is dimensioned so that without exterior support it does not maintain its given shape when the filling goods is filled into the container, or when it is subjected to normal handling such that it must be supported by mechanically, relatively stiff tubular outer sleeve surrounding the inner shell part. Thus, in U.S. Pat. No. 3,355,080, we have a container in which the inner shell is dimensioned so that without exterior support, it does not maintain its given shape at all when the filling goods is filled into the container, or when it is subjected to normal handling forces. In addition, the support for a lid and bottom of the container are provided by the outer shell.
OBJECTIVES OF THE INVENTION
A primary object of the present invention is to provide a container of a multi-wall construction, adapted for packaging purposes.
Another object of the present invention is to provide a high strength, multi-wall container which can be easily and economically produced and still be strong and rigid during use, and reusable as well.
Another object of the present invention is to provide a multi-wall container having an inner shell with a substantially rigid base and rim portion, and a relatively flexible side wall there between, which side wall is coupled to an outer or second wall to form a rigid receptacle adapted for packaging purposes.
Another object of the present invention is to provide a container that permits the exterior shell surface to be preprinted prior to its assembly with the inner shell.
Another object of the present invention is to provide a drinking vessel having a preformed inner shell and preprinted outer shell.
Another object of the present invention is to provide a drinking vessel of a multi-wall construction having an inner shell of a formed thermoplastic material and having an exterior sleeve that is adapted to be secured thereto to provide structural rigidity and insulation.
Another object of the present invention is to provide a receptacle of the general character as described herein and having a cylindrical base portion and a substantially rectangular upper rim portion to obtain maximum usable volume for a nestable container.
SUMMARY OF THE INVENTION
The aforesaid objects of the present invention, and other objects which will become apparent as the description proceeds, are achieved by providing a multi-walled container constructed so as to obviate the difficulties associated with the flexible non-rigid containers presently in use for packaging products.
To provide for the consumer an economically suitable packaging container, that may combine some of the inherent properties and qualities of both plastic and paper, it has been found advantageous to utilize plastic sheet material having a minimum thickness and providing structural rigidity thereto in the base and rim portions thereof. For large packaging containers, the material costs would not economically permit the forming of the wall portion that would permit the stacking of these containers, one above the other when fully packed without the side wall bulging out and perhaps even fracturing. To avoid this and at the same time to permit the manufacturer to properly advise the consumer as to advertising and other information, it has been found that a paper outer shell formed in a frusto-conical configuration may be secured to the exterior surface of the wall portion so that the requisite strength is given to the container and in turn to the package and at the same time, an economically feasible large sized rigid container may be manufactured.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects and advantages of the present invention will become apparent in the following description when taken in connection with the accompanying drawing in which:
FIG. 1 is a perspective exploded view of a container and a closure, therefore constructed in accordance with its present invention;
FIG. 2 is a plan view of the blank which forms the outer shell of the container shown in FIG. 1;
FIG. 3 is a side elevational view of the assembled container of the invention;
FIG. 4 is a sectional view along line 4--4 of FIG. 3;
FIG. 5 is a sectional view along line 5--5 of FIG. 3;
FIG. 6 is a fragmentary sectional view along line 6--6 of FIG. 4;
FIG. 7 is a fragmentary sectional view along line 7--7 of FIG. 5;
FIG. 8 is an enlarged fragmentary sectional view in elevation of two containers constructed in accordance with the present invention and shown in nested-stacked condition;
FIG. 9 is a side view of a double wall container constructed in accordance with the principles of the present invention; and
FIG. 10 is an enlarged fragmentary sectional view of the side wall construction of the container of FIG. 9.
DETAILED DISCUSSION OF THE INVENTION
With specific reference to the form of the present invention illustrated in the drawings, and referring particularly to FIGS. 1 through 5, a container constructed in accordance with the present invention includes an inner walled member or shell 10 surrounded by an outer shell or body member 12. The inner shell 10 is formed from a thermoplastic material and includes a base portion 14, rim portion 16 and a surrounding side wall portion 18 integrally formed therewith and joining the two together. The rim portion 16 forms an open end of the container and has a greater cross-sectional area that of the base portion 14. To provide greater packaging volume, the rim portion 16 is preferably shaped to present a square-like periphery while the base portion 14 is circular, with the wall portion 18 extending upwardly and outwardly so as to merge with the open end rim portion 16.
To provide the requisite structural rigidity and strength to the base portion 14, and as shown more particularly in FIGS. 7 and 8, rigidity means in the form of a truncated conical depression 20 is interiorally disposed within the base portion 14. Additional strength in the base portion 14 is provided by a plurality of retaining embossments 22 in spaced apart relation to each other and formed in the lower extremity of the side wall portion 18 adjoining the base 14. The embossments 22 extend outwardly from the side wall 18 a distance at least equal to the thickness of the outer body portion 12 so as to act as a support for the body portion and prevent it from slipping down off the inner shell side wall portion 18 if not secured thereto by an adhesive during the manufacturing assembly of the container. The actual height and width of the embossments 22 will vary in accordance with the size and wall thickness of the container and the applied load it is intended to withstand in use, with the number of embossments provided, in part determining the degree of structural rigidity of the base portion 14 of the container and surrounding wall portion 18.
In order to maintain a predisposed configuration of and provide rigidity to the container rim portion 16, said portion is formed with an outwardly extending top wall or lip 24 merging with a resilient downwardly extending end wall 26 terminating in a marginal edge 28. The end wall 26 is spaced from the surrounding side wall 18 throughout its entire circumferential extent so as to afford a degree of flexure thereto when a closure 30 is placed thereon (see FIGS. 1, 3 and 6).
The inner shell 10 surrounding side wall portion 18 is of a thin flexible thickness so as to be susceptible to buckling in response to a force applied to the shell rim 16 or base portion 14. To provide the requisite rigidity to the inner shell side wall portion 18, the outer shell 12 is secured in surrounding relation thereto between the rim portion 16 and the base portion 14. The outer shell 12 is preferably fabricated from a plastic or paperboard material formed from a blank 32 as shown in FIG. 2 into a frusto-conical shape (FIG. 1). When initially formed the upper and lower edges 34 and 36 of the conical outer shell lie in parallel planes. Upon assembly to the inner shell 10, the outer shell 12 seats on the thickness defining portions of the embossments 22 in engagement with the outer surface of the inner shell wall portion 18 so as to provide the requisite rigidity thereto, with the outer shell 12 being subjected to a slight deformation such that the upper edge thereof forms a visible arc as seen in FIG. 3 with respect to the upper edge 34 (indicated by the dashed lines). This is due to the shape of the inner shell 10 which as best seen in FIG. 1 is not entirely frusto-conical in that the base 14 is of a circular configuration and the rim 16 essentially a square configuration.
The upper edge 34 of the outer shell 12 forms an arc which is visibly noticeable for certain size containers. Accordingly, it is desirable that the upper edge 34 of the outer shell 12 extend within the area formed by the end wall 26 such that it is not visible when the container assembly is completed, the upper edge 34 thereby being substantially hidden from view. The bottom edge 36 of the outer shell 12 sometimes forms a slight arc, but this is generally not as noticeable and is not so shown in the drawings.
The outer shell 12 may be contoured such that the arc formed by its upper edge 34 additionally acts to support the rim portion 16 by engaging the rim top wall 24 at its contact points as seen in FIG. 8, or the upper edge 34 may be so positioned as to have a minimum clearance between the rim top wall 24 and the edge 34 as for example up to 0.06 inches. In this manner, if the rim portion 16 is depressed during capping it engages the outer shell 12 and is supported thereby. In addition, as seen in FIG. 6 the upper edge 34 at its lowest level at the respective corners of the container is positioned immediately beneath the indentations 61 such that the outer shell tends to support the rim portion at the respective contact points which is important for mechanically capping as well as stacking of loaded containers one above the other. Since the mechanical capping operation introduces a stacked vertical load this load is absorbed in part by the vertical strength of the outer shell 12 in supporting the applied force. In this manner the outer shell therefore aids in providing a structurally rigid container by supporting the side wall 18 as well as, in a sense, the rim portion 16 when the vertically applied force 80 is transmitted to the container.
To facilitate the assembly and retention of the outer shell 12 to the inner shell 10, it has been found desirable to apply an adhesive interiorally to the outer shell after which the shell is slipped over and on to the inner shell in such a fashion that the adhesive upon drying serves to retain the outer shell in the desired position surrounding the inner shell. Alternatively, or in addition, the dimensional relationship of the outer and inner shells may be selected such that the embossments 22 supportively retain the outer shell 12 in the desired position. The embossments 22 may be varied for a line of production molds such that when nested they are different for adjacent containers.
To facilitate of stacking of the respective containers in stack relation to each other, stacking means 38 (see FIGS. 7 and 8) is provided and associated with the inner shell 10 permitting nesting of one container within a like container for stacking purposes thereof when the containers are shipped before they are finally packaged and assembled with the closure means 30 placed thereon. The stacking means 38 includes a plurality of lugs having cylindrically extending inwardly from the wall portion 18 at substantially the bottom thereof, a semi-cylindrical shaped vertical wall 40 forming interruptions of the tapered or sloping wall portion 18 of the container, with the upwardly extending vertical wall 40 terminating in a horizontal portion 42 for receiving the bottoms of the lugs for engagement with the semi-cylindrical shaped horizontal portions of an upper nested container. It has been found that the utilization of the stacking means 38, as shown, as extending from the base 14 of the inner shell 10 provides additional structural rigidity to the inner shell of the container. Although bottom stacking has been illustrated it is appreciated that upper or top stacking may be used in accordance with the invention. In addition the shape of the rim and base portions may be both of a circular or other configuration, as for example as illustrated for the rim portion.
Referring now to FIGS. 1, 4 and 6 the container closure member 30 includes a center cover portion 50 terminating in square like rim portion 52, complimentary to the rim portion 16 of the inner shell 10. The closure rim 52 is integrally formed with the cover portion 50 and includes a vertically oriented outer wall 54 budged at the top by a horizontally disposed portion 56 to an inclined inner wall 58 which merges with the cover portion 50. Although the inner wall 58 has been shown as inclined it has been found that a vertical wall will also permit proper assembly of the package.
To provide structural rigidity to the closure member itself, a plurality of vertically oriented spaced-like rib embossments 60 may be provided along the periphery of the outer wall 54 of the rim 52. In addition, these embossments provide a means for gripping the closure member so as to facilitate its easy covering assembly to and removal from the rest of the container.
To retain the assembled package in axial allignment with another similar package, retention means 44 is provided as seen in FIG. 1 which may consist of an annular ring forming a raised portion on the center cover portion 50 of the closure 30 such that the base portion 14 of a similar container may be positioned therein and prevent lateral movement therebetween when the assembled packages are stored for purchase by the consumer. In addition, the retention means 44 is adapted to retain a disc as by an adhesive or, by other means, which disc can be used for advertising or other purposes.
As seen in FIG. 1, the four locking depressions 61 are provided at the corner of the inner shell 10, but they may vary as to both number, location and size. Provided in the rim portion of the closure member 30 are a plurality of outwardly extending beads 64 located on the inclined inner wall 58. As seen in FIG. 6, these beads mate with the provided indentations 61 so that the two are formed in interlocking complimentary relationship to each other. Both the indentations 61 and the beads 64 are formed with respective inclined portions 66 and 68 such that a predetermined force is required to cause locking engagement therebetween when the closure member 30 is in covering engagement with the inner shell portion 10.
To facilitate the removal or separation of the closure member 30 from the container body, it has been found desirable for certain size container packages to provide removal means in the form of a tab extension 70 on one corner of the marginal edge 28 of the inner shell rim portion end wall 26, and a similar tab extension 72 from a mating corner of the outer wall portion 54 of the closure member 30. The tab extension 72 may be longer than the tab extension 70 to permit separation of the two by the user. The tab extensions 70 and 72 are provided with respective apertures 74 and 76 to accomodate a sealing means 78 in the form of an element which extends through the apertures and is sealed at the packing plant. This provides an essentially tamper proof container package since it is difficult to separate the locking means without gripping the tab extensions 72 and 70. The sealing means may be stapled, sealed, tied or notched.
Accordingly, the tab extensions 70 and 72 are positioned adjacent one of the locking beads 61 and the respective locking bead adjacent said tabs may be provided having a lesser degree of frictional interference than the remaining locking beads to facilitate the removal of the closure 30 by the tab 72.
The dimensional relationship of the outer shell 12 to the wall portion 18 is such as to substantially prevent buckling of the wall portion in response to a force applied to the container. Normally the inner shell 10 of the present invention is so thin and flexible due to the wall portion 18 that even the force applied in positioning the closure 30 on the rim portion 16 having substantial engagement therewith, would undesirably buckle the wall portion 18 if the outer shell 12 is not provided.
It has been found that the degree of structural rigidity to buckling can be defined in that the wall portion 18 is increased in strength by at least a factor of three with respect to a force applied in an axial direction to the container described as compared to a container of a similar construction but without the outer shell 12 thereon.
In accordance with the invention containers may be constructed generally in the range of capacity from less than 1 fluid ounce to as high as 55 gallons, but generally in the range of from 3 to 1,000 fluid ounces, and of a material thickness for the inner shell in the range of from 0.001 inches to 0.20 inches, which may be of plastic materials such as polypropylene, polystyrene, impact polystyrenes, XT polymers, polyethylene, vinyls, and ABS, to name a few. The outer shell 12 may also be in the same range of thickness as the inner shell 10 and of the same or similar plastic material or constructed of a paperboard material.
The container as indicated above might be constructed in various sizes and capacities, but for purposes if illustrating certain aspects of the invention a container package having certain dimensional characteristics has been selected and has an open rim 16 of approximately 110 inches square, with a bottom cross-sectional area of approximately 44 square inches for the approximately 7.5 inch diameter bottom and a height of approximately 9.3 inches to provide a container having a capacity of 320 fluid ounces or approximately 575 cubic inches.
Tests were conducted using containers of the above dimensions having an inner shell 10 of polyproplene material with the wall thickness in the range of from 0.008 to 0.012 inches and the outer shell extending substantially the entire length of the wall portion 18 and being of a paperboard construction having a thickness generally in the range from 0.010 to 0.025 inches. The results showed that the ability of the container wall 18 portion to withstand buckling when a static force was applied in the direction of arrow 80 was increased by a factor of three as compared to the wall portion without the outer shell thereon. Specifically, tests show that when a force of approximately 20 lbs. is applied to the rim portion 16 in the axial direction of arrow 80 the wall portion 18 will buckle when the outer shell 12 is not contained thereon. In contrast to this when the inner shell 10 with the outer shell 12 thereon is subjected to the same test it has been found that the combined wall 18 and outer shell 12 does not buckle until a force of approximately 80 lbs. is applied. Therefore, it can be seen that the outer shell 12 provides the necessary rigidity to the container to produce a functional unit.
The outer shell 12 also provides lateral strength in the direction of arrows 82 or 84 to the container for loads applied from the interior or exterior of the container, for example applied by the contents therein. Tests have shown that for the same container as illustrated above, the ability of the side wall 18 to withstand forces in a lateral direction, before any material change in the configuration thereof, is increased by at least a factor of three, as compared to the container without the outer shell 12 contained thereon. Specifically tests have shown that considerable buckling of the side wall 18, without an outer shell, occurs for the illustrated container when the lateral force is applied either internally or externally. When the wall portion 18 and outer shell are combined the container can withstand substantially greater lateral forces, before any major buckling of the side wall occurs.
When the container of the present invention is used for packaging potato chips and other products containing a certain degree of oil therein it has been found desirable to provide a layer of blocking material or coating 13 as seen in FIG. 1, on the inner surface of the outer shell 12, which coating is capable of forming a barrier for the transmission of ultraviolet sun rays therethrough such that oxidation of the oils in the potato chips within the package is prevented. The coating 13 may take various forms and a simplest expedient is providing a coating of an unbleached material such as brown which retains the dark interior within the package to prevent oxidation of any oils therein.
This ability of containers of the present invention to be economically manufactured and be structurally rigid permits the containers to be utilized for a variety of applications as for example housing light materials such as potato chips or heavier materials such as soap powder, or any other material which would, due to its weight, tend to bulge or buckle the side wall of the container if it were not laterally supported.
ANOTHER EMBODIMENT OF THE INVENTION
Another embodiment of the invention is illustrated in FIGS. 9 and 10, in which the present invention is utilized essentially as a drinking vessel in which the inherent qualities of the outer shell 12a are incorporated for usage as an insulated material. As seen, the inner shell 10a, which contains a substantially rigid base portion 14a and rim portion 16a, includes a wall portion 18a substantially flexible relative to said rim portion 16a and base portion 14a in the same manner as discussed with respect to FIGS. 1 through 8.
The side wall 18a incorporates a plurality of exteriorally disposed peripheral projections, in the form of cylindrical ribs or rings 85a, which are axially spaced and radially offset from one another by the radially directed portions 86a to provide a series of l-shaped segments or stepped portions that terminate in an annular edge 87a. The rings 85a are designed to impart, retain and maintain the outer shell 12a in spaced relation thereto so as to provide an air space in between for insulative purposes. The outer shell 12a acts in the same manner as previously described above to lend structural rigidity to the container and at the same time may be printed so as to have the proper information thereon. The ribs 85a may be found axially extending along the vertical height of the container and function in the same manner as the horizontally extending ribs.
The drinking vessel illustrated in FIGS. 9 and 10 may have a rigid rim portion 16a that is of a conventional design and which provides the necessary structural rigidity to the inner shell 10a such that it may withstand whatever forces are applied thereto. The base portion 14a may be provided with a plurality of embossments 22a which act to retain the outer shell 12a in axial fixed relation to the inner shell 10a and simultaneously to provide structural rigidity to the base portion 18a. A conical depression (not shown) may also be provided on the base portion 14a either for structural rigidity or for bottom stacking if the latter is desired. As illustrated the container may be stacked by stacking means 38a, or the rim portion 16a may be used in a conventional manner.
The outer shell 12a is generally dimensioned such that the mere dimensional relationship between the inner wall surface thereof and the annular edges 87a provide interference fit so that the outer shell 12a is firmly secured thereto. The selection of materials with respect to the inner shell and outer shell may be plastic and paper respectfully, as previously discussed hereinabove. This container provides structural rigidity and is maintained and manufactured at a reasonable cost and also is capable of providing certain insulated characteristics which permits it to be used with a hot or cold liquid comestible.
Many changes and alterations may be made without departing from the spirit and scope of this invention which is set forth in the appended claims which are to be construed as broadly as possible in view of the prior art.
1. Field of the Invention
The present invention relates to multi-walled packages in general and particularly to multi-walled containers of the type adapted to be nested one within the other, said outer shell construction joined together in a manner in which the structural rigidity of the containers are provided by a novel coupling of interrelated portions of the inner and outer shells.
In the packaging industry today there exists for a number of products such as potato chips and related snack foods, flexible bag packages. These packages range in weight from a fraction of an ounce to over two pounds. The materials used for the manufacturer of such bags are generally of a cellophane-polypropylene laminate. The present packages are such that they cannot easily be stacked on the shelf, they have difficulty in packaging them for shipment and they consume considerable space, that could be more economically occupied. With these difficulties in mind, applicants set out to provide a rigid container that would provide a sufficiently long shelf life to the product packaged therein, one having distinctive configuration for good merchandising appeal, with utilization of storage capacity and a suitable surface on the package and closure for graphic display.
Although the principles of the present invention are broadly applicable to packages, including receptacles, containers and cups, for comestibles of various forms, solids, fluids both hot and cold, the present invention is particularly adapted for use in conjunction with food packaging containers, providing storage of comestibles therein and hence it has been generally so illustrated and will be so described.
2. DESCRIPTION OF THE PRIOR ART
Heretofore, a number of packages have been proposed that have dealt broadly with the use of multiple layers to form the walls thereof and may be generally defined as double walled or multi-wall containers. The construction of these containers have generally fallen into two basic areas.
The first area, deals with insulated containers, that are adapted primarily to be used as a drinking vessel, and which may be manufactured out of a high density plastic material such as polystyrene or, in turn, out of a foamed polystyrene material that is generally bonded to another material which may be paper or plastic. Examples of insulated containers of this nature are disclosed, for example, in U.S. Pat. Nos. 3,079,027; 3,049,277; 2,853,222 and RE 25,618, and others which are well-known in the art.
Essentially, this group of patents is directed to providing an insulated container to be used as a drinking vessel in which the comestible contained therein may be retained at the proper elevated temperature. The construction of these containers is essentially one in which we have a substantially structurally rigid inner shell portion, that has secured thereto an outer shell portion and the insulating characteristics of the container are obtained by having either the inner and outer shells in spaced relationship to each other, or forming one or both of the shells of a plastic insulative material such as foam polystyrene or an equivalent. This type of construction is essentially not related to the present invention in that both shells are structurally rigid and not interdependent on each other for strength.
The second area, in contrast to the above, which is disclosed in a number of prior patents, generally relates to containers in which we have a structurally rigid exterior shell and in which the interior surface is essentially formed of a very thin, flexible sheet material, which has not a permanent configuration or structural rigidity and relies entirely on the outer shell to provide the requisite form of the container. For example, in the U.S. Pat. No. 3,150,811, we have a container in which we have an inner liner that is of a resilient plastic material adhered to the interior of the container.
U.S. Pat. No. 3,355,080, also discloses a container which is of essentially similar construction in that there is a tubular inner-shell, and as stated in the patent, is dimensioned so that without exterior support it does not maintain its given shape when the filling goods is filled into the container, or when it is subjected to normal handling such that it must be supported by mechanically, relatively stiff tubular outer sleeve surrounding the inner shell part. Thus, in U.S. Pat. No. 3,355,080, we have a container in which the inner shell is dimensioned so that without exterior support, it does not maintain its given shape at all when the filling goods is filled into the container, or when it is subjected to normal handling forces. In addition, the support for a lid and bottom of the container are provided by the outer shell.
OBJECTIVES OF THE INVENTION
A primary object of the present invention is to provide a container of a multi-wall construction, adapted for packaging purposes.
Another object of the present invention is to provide a high strength, multi-wall container which can be easily and economically produced and still be strong and rigid during use, and reusable as well.
Another object of the present invention is to provide a multi-wall container having an inner shell with a substantially rigid base and rim portion, and a relatively flexible side wall there between, which side wall is coupled to an outer or second wall to form a rigid receptacle adapted for packaging purposes.
Another object of the present invention is to provide a container that permits the exterior shell surface to be preprinted prior to its assembly with the inner shell.
Another object of the present invention is to provide a drinking vessel having a preformed inner shell and preprinted outer shell.
Another object of the present invention is to provide a drinking vessel of a multi-wall construction having an inner shell of a formed thermoplastic material and having an exterior sleeve that is adapted to be secured thereto to provide structural rigidity and insulation.
Another object of the present invention is to provide a receptacle of the general character as described herein and having a cylindrical base portion and a substantially rectangular upper rim portion to obtain maximum usable volume for a nestable container.
SUMMARY OF THE INVENTION
The aforesaid objects of the present invention, and other objects which will become apparent as the description proceeds, are achieved by providing a multi-walled container constructed so as to obviate the difficulties associated with the flexible non-rigid containers presently in use for packaging products.
To provide for the consumer an economically suitable packaging container, that may combine some of the inherent properties and qualities of both plastic and paper, it has been found advantageous to utilize plastic sheet material having a minimum thickness and providing structural rigidity thereto in the base and rim portions thereof. For large packaging containers, the material costs would not economically permit the forming of the wall portion that would permit the stacking of these containers, one above the other when fully packed without the side wall bulging out and perhaps even fracturing. To avoid this and at the same time to permit the manufacturer to properly advise the consumer as to advertising and other information, it has been found that a paper outer shell formed in a frusto-conical configuration may be secured to the exterior surface of the wall portion so that the requisite strength is given to the container and in turn to the package and at the same time, an economically feasible large sized rigid container may be manufactured.
BRIEF DESCRIPTION OF THE DRAWINGS
Other and further objects and advantages of the present invention will become apparent in the following description when taken in connection with the accompanying drawing in which:
FIG. 1 is a perspective exploded view of a container and a closure, therefore constructed in accordance with its present invention;
FIG. 2 is a plan view of the blank which forms the outer shell of the container shown in FIG. 1;
FIG. 3 is a side elevational view of the assembled container of the invention;
FIG. 4 is a sectional view along line 4--4 of FIG. 3;
FIG. 5 is a sectional view along line 5--5 of FIG. 3;
FIG. 6 is a fragmentary sectional view along line 6--6 of FIG. 4;
FIG. 7 is a fragmentary sectional view along line 7--7 of FIG. 5;
FIG. 8 is an enlarged fragmentary sectional view in elevation of two containers constructed in accordance with the present invention and shown in nested-stacked condition;
FIG. 9 is a side view of a double wall container constructed in accordance with the principles of the present invention; and
FIG. 10 is an enlarged fragmentary sectional view of the side wall construction of the container of FIG. 9.
DETAILED DISCUSSION OF THE INVENTION
With specific reference to the form of the present invention illustrated in the drawings, and referring particularly to FIGS. 1 through 5, a container constructed in accordance with the present invention includes an inner walled member or shell 10 surrounded by an outer shell or body member 12. The inner shell 10 is formed from a thermoplastic material and includes a base portion 14, rim portion 16 and a surrounding side wall portion 18 integrally formed therewith and joining the two together. The rim portion 16 forms an open end of the container and has a greater cross-sectional area that of the base portion 14. To provide greater packaging volume, the rim portion 16 is preferably shaped to present a square-like periphery while the base portion 14 is circular, with the wall portion 18 extending upwardly and outwardly so as to merge with the open end rim portion 16.
To provide the requisite structural rigidity and strength to the base portion 14, and as shown more particularly in FIGS. 7 and 8, rigidity means in the form of a truncated conical depression 20 is interiorally disposed within the base portion 14. Additional strength in the base portion 14 is provided by a plurality of retaining embossments 22 in spaced apart relation to each other and formed in the lower extremity of the side wall portion 18 adjoining the base 14. The embossments 22 extend outwardly from the side wall 18 a distance at least equal to the thickness of the outer body portion 12 so as to act as a support for the body portion and prevent it from slipping down off the inner shell side wall portion 18 if not secured thereto by an adhesive during the manufacturing assembly of the container. The actual height and width of the embossments 22 will vary in accordance with the size and wall thickness of the container and the applied load it is intended to withstand in use, with the number of embossments provided, in part determining the degree of structural rigidity of the base portion 14 of the container and surrounding wall portion 18.
In order to maintain a predisposed configuration of and provide rigidity to the container rim portion 16, said portion is formed with an outwardly extending top wall or lip 24 merging with a resilient downwardly extending end wall 26 terminating in a marginal edge 28. The end wall 26 is spaced from the surrounding side wall 18 throughout its entire circumferential extent so as to afford a degree of flexure thereto when a closure 30 is placed thereon (see FIGS. 1, 3 and 6).
The inner shell 10 surrounding side wall portion 18 is of a thin flexible thickness so as to be susceptible to buckling in response to a force applied to the shell rim 16 or base portion 14. To provide the requisite rigidity to the inner shell side wall portion 18, the outer shell 12 is secured in surrounding relation thereto between the rim portion 16 and the base portion 14. The outer shell 12 is preferably fabricated from a plastic or paperboard material formed from a blank 32 as shown in FIG. 2 into a frusto-conical shape (FIG. 1). When initially formed the upper and lower edges 34 and 36 of the conical outer shell lie in parallel planes. Upon assembly to the inner shell 10, the outer shell 12 seats on the thickness defining portions of the embossments 22 in engagement with the outer surface of the inner shell wall portion 18 so as to provide the requisite rigidity thereto, with the outer shell 12 being subjected to a slight deformation such that the upper edge thereof forms a visible arc as seen in FIG. 3 with respect to the upper edge 34 (indicated by the dashed lines). This is due to the shape of the inner shell 10 which as best seen in FIG. 1 is not entirely frusto-conical in that the base 14 is of a circular configuration and the rim 16 essentially a square configuration.
The upper edge 34 of the outer shell 12 forms an arc which is visibly noticeable for certain size containers. Accordingly, it is desirable that the upper edge 34 of the outer shell 12 extend within the area formed by the end wall 26 such that it is not visible when the container assembly is completed, the upper edge 34 thereby being substantially hidden from view. The bottom edge 36 of the outer shell 12 sometimes forms a slight arc, but this is generally not as noticeable and is not so shown in the drawings.
The outer shell 12 may be contoured such that the arc formed by its upper edge 34 additionally acts to support the rim portion 16 by engaging the rim top wall 24 at its contact points as seen in FIG. 8, or the upper edge 34 may be so positioned as to have a minimum clearance between the rim top wall 24 and the edge 34 as for example up to 0.06 inches. In this manner, if the rim portion 16 is depressed during capping it engages the outer shell 12 and is supported thereby. In addition, as seen in FIG. 6 the upper edge 34 at its lowest level at the respective corners of the container is positioned immediately beneath the indentations 61 such that the outer shell tends to support the rim portion at the respective contact points which is important for mechanically capping as well as stacking of loaded containers one above the other. Since the mechanical capping operation introduces a stacked vertical load this load is absorbed in part by the vertical strength of the outer shell 12 in supporting the applied force. In this manner the outer shell therefore aids in providing a structurally rigid container by supporting the side wall 18 as well as, in a sense, the rim portion 16 when the vertically applied force 80 is transmitted to the container.
To facilitate the assembly and retention of the outer shell 12 to the inner shell 10, it has been found desirable to apply an adhesive interiorally to the outer shell after which the shell is slipped over and on to the inner shell in such a fashion that the adhesive upon drying serves to retain the outer shell in the desired position surrounding the inner shell. Alternatively, or in addition, the dimensional relationship of the outer and inner shells may be selected such that the embossments 22 supportively retain the outer shell 12 in the desired position. The embossments 22 may be varied for a line of production molds such that when nested they are different for adjacent containers.
To facilitate of stacking of the respective containers in stack relation to each other, stacking means 38 (see FIGS. 7 and 8) is provided and associated with the inner shell 10 permitting nesting of one container within a like container for stacking purposes thereof when the containers are shipped before they are finally packaged and assembled with the closure means 30 placed thereon. The stacking means 38 includes a plurality of lugs having cylindrically extending inwardly from the wall portion 18 at substantially the bottom thereof, a semi-cylindrical shaped vertical wall 40 forming interruptions of the tapered or sloping wall portion 18 of the container, with the upwardly extending vertical wall 40 terminating in a horizontal portion 42 for receiving the bottoms of the lugs for engagement with the semi-cylindrical shaped horizontal portions of an upper nested container. It has been found that the utilization of the stacking means 38, as shown, as extending from the base 14 of the inner shell 10 provides additional structural rigidity to the inner shell of the container. Although bottom stacking has been illustrated it is appreciated that upper or top stacking may be used in accordance with the invention. In addition the shape of the rim and base portions may be both of a circular or other configuration, as for example as illustrated for the rim portion.
Referring now to FIGS. 1, 4 and 6 the container closure member 30 includes a center cover portion 50 terminating in square like rim portion 52, complimentary to the rim portion 16 of the inner shell 10. The closure rim 52 is integrally formed with the cover portion 50 and includes a vertically oriented outer wall 54 budged at the top by a horizontally disposed portion 56 to an inclined inner wall 58 which merges with the cover portion 50. Although the inner wall 58 has been shown as inclined it has been found that a vertical wall will also permit proper assembly of the package.
To provide structural rigidity to the closure member itself, a plurality of vertically oriented spaced-like rib embossments 60 may be provided along the periphery of the outer wall 54 of the rim 52. In addition, these embossments provide a means for gripping the closure member so as to facilitate its easy covering assembly to and removal from the rest of the container.
To retain the assembled package in axial allignment with another similar package, retention means 44 is provided as seen in FIG. 1 which may consist of an annular ring forming a raised portion on the center cover portion 50 of the closure 30 such that the base portion 14 of a similar container may be positioned therein and prevent lateral movement therebetween when the assembled packages are stored for purchase by the consumer. In addition, the retention means 44 is adapted to retain a disc as by an adhesive or, by other means, which disc can be used for advertising or other purposes.
As seen in FIG. 1, the four locking depressions 61 are provided at the corner of the inner shell 10, but they may vary as to both number, location and size. Provided in the rim portion of the closure member 30 are a plurality of outwardly extending beads 64 located on the inclined inner wall 58. As seen in FIG. 6, these beads mate with the provided indentations 61 so that the two are formed in interlocking complimentary relationship to each other. Both the indentations 61 and the beads 64 are formed with respective inclined portions 66 and 68 such that a predetermined force is required to cause locking engagement therebetween when the closure member 30 is in covering engagement with the inner shell portion 10.
To facilitate the removal or separation of the closure member 30 from the container body, it has been found desirable for certain size container packages to provide removal means in the form of a tab extension 70 on one corner of the marginal edge 28 of the inner shell rim portion end wall 26, and a similar tab extension 72 from a mating corner of the outer wall portion 54 of the closure member 30. The tab extension 72 may be longer than the tab extension 70 to permit separation of the two by the user. The tab extensions 70 and 72 are provided with respective apertures 74 and 76 to accomodate a sealing means 78 in the form of an element which extends through the apertures and is sealed at the packing plant. This provides an essentially tamper proof container package since it is difficult to separate the locking means without gripping the tab extensions 72 and 70. The sealing means may be stapled, sealed, tied or notched.
Accordingly, the tab extensions 70 and 72 are positioned adjacent one of the locking beads 61 and the respective locking bead adjacent said tabs may be provided having a lesser degree of frictional interference than the remaining locking beads to facilitate the removal of the closure 30 by the tab 72.
The dimensional relationship of the outer shell 12 to the wall portion 18 is such as to substantially prevent buckling of the wall portion in response to a force applied to the container. Normally the inner shell 10 of the present invention is so thin and flexible due to the wall portion 18 that even the force applied in positioning the closure 30 on the rim portion 16 having substantial engagement therewith, would undesirably buckle the wall portion 18 if the outer shell 12 is not provided.
It has been found that the degree of structural rigidity to buckling can be defined in that the wall portion 18 is increased in strength by at least a factor of three with respect to a force applied in an axial direction to the container described as compared to a container of a similar construction but without the outer shell 12 thereon.
In accordance with the invention containers may be constructed generally in the range of capacity from less than 1 fluid ounce to as high as 55 gallons, but generally in the range of from 3 to 1,000 fluid ounces, and of a material thickness for the inner shell in the range of from 0.001 inches to 0.20 inches, which may be of plastic materials such as polypropylene, polystyrene, impact polystyrenes, XT polymers, polyethylene, vinyls, and ABS, to name a few. The outer shell 12 may also be in the same range of thickness as the inner shell 10 and of the same or similar plastic material or constructed of a paperboard material.
The container as indicated above might be constructed in various sizes and capacities, but for purposes if illustrating certain aspects of the invention a container package having certain dimensional characteristics has been selected and has an open rim 16 of approximately 110 inches square, with a bottom cross-sectional area of approximately 44 square inches for the approximately 7.5 inch diameter bottom and a height of approximately 9.3 inches to provide a container having a capacity of 320 fluid ounces or approximately 575 cubic inches.
Tests were conducted using containers of the above dimensions having an inner shell 10 of polyproplene material with the wall thickness in the range of from 0.008 to 0.012 inches and the outer shell extending substantially the entire length of the wall portion 18 and being of a paperboard construction having a thickness generally in the range from 0.010 to 0.025 inches. The results showed that the ability of the container wall 18 portion to withstand buckling when a static force was applied in the direction of arrow 80 was increased by a factor of three as compared to the wall portion without the outer shell thereon. Specifically, tests show that when a force of approximately 20 lbs. is applied to the rim portion 16 in the axial direction of arrow 80 the wall portion 18 will buckle when the outer shell 12 is not contained thereon. In contrast to this when the inner shell 10 with the outer shell 12 thereon is subjected to the same test it has been found that the combined wall 18 and outer shell 12 does not buckle until a force of approximately 80 lbs. is applied. Therefore, it can be seen that the outer shell 12 provides the necessary rigidity to the container to produce a functional unit.
The outer shell 12 also provides lateral strength in the direction of arrows 82 or 84 to the container for loads applied from the interior or exterior of the container, for example applied by the contents therein. Tests have shown that for the same container as illustrated above, the ability of the side wall 18 to withstand forces in a lateral direction, before any material change in the configuration thereof, is increased by at least a factor of three, as compared to the container without the outer shell 12 contained thereon. Specifically tests have shown that considerable buckling of the side wall 18, without an outer shell, occurs for the illustrated container when the lateral force is applied either internally or externally. When the wall portion 18 and outer shell are combined the container can withstand substantially greater lateral forces, before any major buckling of the side wall occurs.
When the container of the present invention is used for packaging potato chips and other products containing a certain degree of oil therein it has been found desirable to provide a layer of blocking material or coating 13 as seen in FIG. 1, on the inner surface of the outer shell 12, which coating is capable of forming a barrier for the transmission of ultraviolet sun rays therethrough such that oxidation of the oils in the potato chips within the package is prevented. The coating 13 may take various forms and a simplest expedient is providing a coating of an unbleached material such as brown which retains the dark interior within the package to prevent oxidation of any oils therein.
This ability of containers of the present invention to be economically manufactured and be structurally rigid permits the containers to be utilized for a variety of applications as for example housing light materials such as potato chips or heavier materials such as soap powder, or any other material which would, due to its weight, tend to bulge or buckle the side wall of the container if it were not laterally supported.
ANOTHER EMBODIMENT OF THE INVENTION
Another embodiment of the invention is illustrated in FIGS. 9 and 10, in which the present invention is utilized essentially as a drinking vessel in which the inherent qualities of the outer shell 12a are incorporated for usage as an insulated material. As seen, the inner shell 10a, which contains a substantially rigid base portion 14a and rim portion 16a, includes a wall portion 18a substantially flexible relative to said rim portion 16a and base portion 14a in the same manner as discussed with respect to FIGS. 1 through 8.
The side wall 18a incorporates a plurality of exteriorally disposed peripheral projections, in the form of cylindrical ribs or rings 85a, which are axially spaced and radially offset from one another by the radially directed portions 86a to provide a series of l-shaped segments or stepped portions that terminate in an annular edge 87a. The rings 85a are designed to impart, retain and maintain the outer shell 12a in spaced relation thereto so as to provide an air space in between for insulative purposes. The outer shell 12a acts in the same manner as previously described above to lend structural rigidity to the container and at the same time may be printed so as to have the proper information thereon. The ribs 85a may be found axially extending along the vertical height of the container and function in the same manner as the horizontally extending ribs.
The drinking vessel illustrated in FIGS. 9 and 10 may have a rigid rim portion 16a that is of a conventional design and which provides the necessary structural rigidity to the inner shell 10a such that it may withstand whatever forces are applied thereto. The base portion 14a may be provided with a plurality of embossments 22a which act to retain the outer shell 12a in axial fixed relation to the inner shell 10a and simultaneously to provide structural rigidity to the base portion 18a. A conical depression (not shown) may also be provided on the base portion 14a either for structural rigidity or for bottom stacking if the latter is desired. As illustrated the container may be stacked by stacking means 38a, or the rim portion 16a may be used in a conventional manner.
The outer shell 12a is generally dimensioned such that the mere dimensional relationship between the inner wall surface thereof and the annular edges 87a provide interference fit so that the outer shell 12a is firmly secured thereto. The selection of materials with respect to the inner shell and outer shell may be plastic and paper respectfully, as previously discussed hereinabove. This container provides structural rigidity and is maintained and manufactured at a reasonable cost and also is capable of providing certain insulated characteristics which permits it to be used with a hot or cold liquid comestible.
Many changes and alterations may be made without departing from the spirit and scope of this invention which is set forth in the appended claims which are to be construed as broadly as possible in view of the prior art.