DETAILED DESCRIPTION OF THE INVENTION

[0026] The present invention is directed to a packaging system that has several unique features or purposes that may be present alone or in combination including, but not limited to, dosing (which may be accomplished by inhalation due to panel shape restoration or resitution or vacuum), providing an integral spoon or measuring device, using a stiffening ring, container reinforcement, and sieve decanting.

[0027] As shown in FIGS. 1 and 2, one preferred embodiment of the present invention includes the elements of a container 20 (e.g. jar, bottle, cup, glass, or other type of flexible or rigid holding package), a stiffening ring 22 (shown as 22a in FIG. 3, 22b in FIG. 4, and 22c in FIG. 5) a stopper 24 (shown as 24a in FIG. 3, 24b in FIG. 4, and 24c in FIG. 5), and a cap 26. For certain features, some of these elements may be unnecessary. It is also possible that some of the elements may be combined. These elements are discussed individually.

[0028] A container 20 of the present invention, as shown in FIGS. 1 and 2, is meant to house “product” 30 such as food (e.g. fruit, yogurt, juices), medicine, liquids, solids, or slurries. It is also possible that the container 20 may be empty.

[0029] One preferred embodiment of a container 20 is a flexible container such as a blown plastic container 20 with walls 32 and a weaker bottom panel 34. The bottom panel 34 is designed to be deflectable such that the condensation of water vapor at an elevated temperature to liquid water causes bottom panel 34 deflection as the headspace volume goes to zero upon cooling. This is significant because if the bottom panel 34 deflects, no distortion in the walls 32 is caused as the headspace volume goes to zero upon cooling.

[0030] The flexible container 20 may be constructed using such methods as standard blow molding, stretch blow molding, standard PET, hot fill PET, heat set PET, CPET, pressure, or thermoformed plastics, injection molding, and other processes developed to create flexible containers. Flexible containers 20 may also be made of alternative materials (e.g. rubber, laminated plastic, and metal foils) and by alternative methods.

[0031] The container 20 may be made of non-flexible or rigid material such as glass, metal, ceramic, or other rigid materials. A rigid container 20 may be used in embodiments in which panel deflection is unnecessary or is not necessary because other elements of the system have sufficient deflection or a vacuum causes the container to inhale rather than panel shape restoration.

[0032] In one preferred embodiment, such as one to be used with the elements shown in FIG. 3, a set of left-handed threads 36a is constructed along the outer diameter of the lip of the container 20. The left-handed threads 36a of the container 20 are designed to mate with the left-handed threads 36b of the stiffening ring 22. With the embodiments shown in FIGS. 4 and 5, the direction of the threading 36a, 36b, may be irrelevant. Further, other types of removable connection means could be used to connect the container 20 to the stiffening ring 22 including, but not limited to threads, lugs, snap rings, or any other suitable sealing mechanism. Still further, in other embodiments, the stiffening ring may be part of the container or may be attached with permanent connection means.

[0033] FIG. 3 shows a first preferred embodiment of a stiffening ring 22a and a stopper 24a that mate using thread connection means 38a, 38b.

[0034] The stiffening ring 22a is an actual ring with no central portion. The ring itself, in cross section, is shaped like an upside-down “U.” In this embodiment there are two sets of threads: a set of right-handed threads 38b along the inner diameter of the inner “U” leg and a set of left-handed threads 36b along the inner diameter of the outer “U” leg. The set of right-handed threads 38b along the inner diameter of the inner “U” leg preferably has at least one dosing channel 40 defined substantially perpendicularly to the threads 38b. The left-handed threads 36b along the inner diameter of the outer “U” leg are designed to mate with the left-handed threads 36a of the container 20. The right-handed threads 38b along the inner diameter of the inner “U” leg are designed to mate with the right-handed threads 38a of the stopper 24a.

[0035] The stopper 24a is shown as being shaped as an upside-down flattened top hat with a top portion and a brim. The outer diameter of the top portion of the top hat has a set of right-handed threads 38a defined thereon. The set of right-handed threads 38a along the outer diameter preferably has at least one dosing cavity 42 (for holding dosing material 43 (FIG. 2) such as medicine, essential fatty acids, active enzymes, powdered colors, aromas, flavors, or any labile ingredients, defined just above or in the threads 38b. The top surface of the top portion of the top hat, the “stopper panel” 44, preferably is deflectable. This deflectable stopper panel 44 is designed to deflect such that energy is stored when a headspace gas collapses in a container, thus creating additional potential for inhalation into a zero headspace container as the container is opened and the panel shape prior to sealing is restored.

[0036] Using the embodiment of the stiffening ring 22a and stopper 24a shown in FIG. 3, the dosing material 43 is inhaled into product 30 in the container 20 when the channel 40 passes the cavity 42. For the inhalation feature in this embodiment, it is important that the cavity 42 be askew from the channel 40 when the stiffening ring 22a/stopper 24a unit is assembled. Registration notches (not shown) or other mechanical means know in the industry may be used for this purpose.

[0037] FIG. 4 shows a second preferred embodiment of a stiffening ring 22b and a stopper 24b.

[0038] The stiffening ring 22b in this embodiment, like the stiffening ring 22a in FIG. 3, is shaped like an upside-down “U.” In addition, this embodiment of the stiffening ring 22b has a ring flange 46 with at least one breakaway feature 48. The ring flange 46 is constructed annularly along the inner diameter of the of the inner diameter of the inner “U” leg. In this shown embodiment the inner diameter of the inner “U” leg 54b is smooth and is designed to mate with the outer diameter of the top portion 54a of the stopper 24b.

[0039] The stopper 24b is shown as being shaped as a hollow upside-down flattened top hat with a top portion, a brim, and a pull tab 49. The outer diameter of the top portion 54a of the top hat is preferably smooth. The outer diameter 54a preferably has at least one dosing cavity 42 defined therein. The top surface of the top portion of the top hat, the “stopper panel” 44, is preferably deflectable. It should be noted that this structure is particularly suitable for housing almost any type contents that, for exemplary purposes only, could be as diverse as a folded spoon, additional additives, or instructions for use.

[0040] When the stiffening ring 22b and stopper 24b are placed into mating relationship, they may be joined or integrated so as to form a single unit. This may be done through the use of an inductive seal, fusing, adhesive, pressure fitting, and sonic welding. In the shown embodiment, the outer diameter 54a of the top portion 54a of the stopper 24b may be integrated with a portion of the inner diameter of the inner “U” leg 54b of the stiffening ring 22b to seal off the dosing cavity 42 from external contamination. In other words, only the portion of the inner diameter of the inner “U” leg 54b substantially adjacent to the dosing cavity 42 is attached. Also, in the shown embodiment, the outer diameter of the stopper panel 44 of the stopper 24b may be integrated with the upper surface of the ring flange 46 of the stiffening ring 22b. When the pull tab 39 is pulled, the breakaway feature 48 causes the ring flange 46 to disengage from the stiffening ring 22b and be removed with the entire stopper 24b.

[0041] In one preferred embodiment, when the stiffening ring 22b and stopper 24b are an integral unit, the dosing cavity 42 is positioned to be in relatively close relationship with the at least one breakaway feature 48. The proximity of dosing cavity 42 to the breakaway feature 48 causes the dosing material 43 to be inhaled as the ring flange 46 breaks off the stiffening ring 22b.

[0042] In one preferred embodiment, when the stiffening ring 22b and stopper 24b are an integral unit, the ring flange 46 still allows the stopper panel 44 to deflect such that energy is stored when a headspace gas collapses in a container, thus creating additional potential for inhalation into a zero headspace or vacuum headspace container as the container is opened.

[0043] FIG. 5 shows a third preferred embodiment of a stiffening ring 22c and a stopper 24c.

[0044] The stiffening ring 22c in this embodiment has a central ring panel 50 or diaphragm with at least one breakaway feature 52. In one preferred embodiment, this central ring panel 50 is deflectable. The ring itself, in cross section, is shaped like an upside-down “U” and the central ring panel 50 extends completely within the inner diameter of the of the inner “U” leg. In this embodiment the inner diameter of the inner “U” leg 54b is smooth and is designed to mate with the outer diameter of the top portion 54a of the stopper 24c.

[0045] The stopper 24c is shown as being shaped as a solid upside-down flattened top hat with a top portion, a brim, and a pull tab 49. The outer diameter of the top portion 54a of the top hat is preferably smooth. The outer diameter 54a preferably has at least one dosing cavity 42 defined therein. The top surface of the top portion of the top hat, the “stopper panel” 44, preferably is deflectable.

[0046] When the stiffening ring 22c and stopper 24c are placed into mating relationship, they may be joined or integrated so as to form a single unit. This may be done through the use of an inductive seal, fusing, adhesive, pressure fitting, and sonic welding. In the shown embodiment, the outer diameter 54a of the top portion 54a of the stopper 24c may be integrated with a portion of the inner diameter of the inner “U” leg 54b of the stiffening ring 22c to seal off the dosing cavity 42 from external contamination. Also, in the shown embodiment, the outer diameter of the stopper panel 44 of the stopper 24c may be integrated with the upper surface of the central ring panel 50 of the stiffening ring 22c. When the pull tab 39 is pulled, the breakaway feature 53 causes the central ring panel 50 to disengage from the stiffening ring 22c and be removed with the entire stopper 24c.

[0047] In one preferred embodiment, when the stiffening ring 22c and stopper 24c are an integral unit, the dosing cavity 42 is positioned to be in relatively close relationship with the at least one breakaway feature 52. The proximity of dosing cavity 42 to the breakaway feature 52 causes the dosing material 43 to be inhaled as the central ring panel 50 breaks off the stiffening ring 22c.

[0048] In one preferred embodiment, when the stiffening ring 22c and stopper 24c are an integral unit, the central ring panel 50 still allows the stopper panel 44 to deflect such that energy is stored when a headspace gas collapses in a container, thus creating additional potential for inhalation into a zero headspace or vacuum headspace container as the container is opened.

[0049] It should be noted that alternative embodiments of the stopper 24a, 24b, 24c could have part or all of the upper portion filled so that it is a solid unit (FIG. 5), partially filled (not shown) with ribbing, braces, or support structure to reinforce the outer diameter 54a, or hollow (FIG. 4).

[0050] It should be noted that some of the elements of the embodiments shown in FIGS. 3-5 are described in a single manner for convenience. For example, the “left-handed” and “right-handed” threads of FIG. 3 could have been reversed (and their mating surfaces similarly reversed). Further, although the threads are shown as continuous threads, alternative embodiments could use lugs or retaining snaps. Similarly, as shown in the embodiments of FIGS. 4 and 5, in some embodiments threads are not needed and press-fitting, adhering, gasketing, or integral construction could be used in place of the threads.

[0051] One feature provided by the stiffening ring 22 is that it allows the container 20 to be blown lighter than would otherwise be possible, thereby creating a cost savings. It also provides an improved lip that assists in the decanting of liquid.

[0052] A cap 26 is also included in one preferred embodiment of the present invention. The cap 26 may have an indent suitable to accommodate “cap contents” such as a spoon, folded spoon 60, measuring device, prize, or any desired content. A label or seal may be placed over the indent to keep the contents therein clean. It should be noted that in alternative embodiments the cap 26 contents could be placed between the cap 26 and the stopper 24. It should also be noted that the cap 26 and the stopper 24 may be an integral unit. As shown in FIGS. 4 and 5, a cap 26 may be omitted entirely.

[0053] One of the primary features of the present invention is dosing through the use of inhalation by panel restoration or vacuum. If dosing is a desired feature, dosing material 43 is preloaded into the dosing cavity 42. Opening the system by removing the stopper 24 causes the system to “inhale” the dosing material 43 into the container 20 where the dosing material 43 can mix with the product 30 therein.

[0054] FIGS. 6 and 7 show two exemplary methods through which the methods of the present invention could be implemented. These methods are meant to be exemplary and are not meant to limit the scope of the invention. For example, steps shown in phantom are considered optional.

[0055] Using the embodiment shown in FIG. 3 according to the process shown in FIG. 6, the dosing material 43 is preloaded 70 into the dosing cavity 42. The stopper 24a is then connected 72 to the stiffening ring 22a using the mating right-handed threads 38a, 38b. Although not shown in phantom, it should be noted that these steps may be optional if the dosing material 43 came preloaded in a pre-configured stopper 22a/stiffening ring 24a unit.

[0056] The container 20 is filled 74 with the product 30. In the preferred embodiment of FIG. 6, the product 30 is hot when it is placed in the container 20 because this embodiment anticipates the use of the hot and hold method. An outside source of steam removes then all non-condensable gases 76 thereby filling the head space with water. This step is shown as optional because a vacuum could also be drawn directly.

[0057] The container is then capped or sealed 78 so as to create a vacuum within the container 20. As set forth above, vacuum may be created using methods such as the hot fill and hold method or a vacuum fill may be used 76. In the shown embodiment of FIG. 6, the hot fill and hold method is used. Then the product 30 is sealed in the container 20 using the combined stopper 24a/stiffening ring 22a. It should be noted that other methods or apparatus could be used to seal the container 20. Eventually, the head space gas collapses 80 to water to create 82 a vacuum and/or eliminate 84 the head space in a flexible container. The deflection 86 of the bottom panel 34 of the container 20 and the deflectable stopper panel 44 of the stopper 24a “stores energy” and helps increase the vacuum pressure. It should be noted, however, deflection is optional and rigid components may be used.

[0058] The cap 26 may be placed 88 on the combined stopper 24a/stiffening ring 22b prior to combination being attached to the container 20, after the combination is attached to the container 20. The cap 26 may be fused, press fitted, adhered, welded, or otherwise connected to the stopper 24a. Alternate embodiments could eliminate the cap 26 or make the cap 26 and stopper 24a an integral unit. As mentioned above, in the preferred embodiment of FIG. 3, the left-handed threads 36b along the inner diameter of the outer “U” leg are designed to mate with the left-handed threads 36a of the container 20. When the product is placed in the container 20, the stiffening ring 22a mates to the container 20 “left-handed.” The consumer, however, would not normally open a container 20 left-handed. Accordingly, when the consumer attempted to open the container 20 right-handed, only the stopper 24a (and possibly the cap 26) can unscrew.

[0059] When the consumer opens 90 the packaging system using the right-handed threading 38a, 38b, the dosing channel 40 would pass 92 the dosing cavity 42. The vacuum or stored energy of the deflected panel 34 within the container 20 is released 94 as the dosing cavity 42 passes the dosing channel 40. A dose of a precise small quantity the dosing material 43 is inhaled 96 into the container 20 by the vacuum which is released as the dosing cavity 42 passes the dosing channel 40. The opening of the closure is intuitive to the consumer; i.e., little or no training or instructions are necessary.

[0060] Using the embodiment shown in FIG. 4 according to the process shown in FIG. 7, the dosing material 43 is preloaded 170 into the dosing cavity 42. The stopper 24b is then connected 172 to the stiffening ring 22b by insertion and fusing. In one preferred embodiment, when the stiffening ring 22b and stopper 24b are an integral unit, the dosing cavity 42 is positioned to be in relatively close relationship with at least one breakaway feature 52. Further, in one preferred embodiment the process of fusing also at least partially attaches the central ring panel 50 to the stopper panel 44.

[0061] Next, container 20 is filled 174 with the product 30. In the preferred embodiment of FIG. 7, the product 30 is hot when it is placed in the container 20 because this embodiment anticipates the use of the hot and hold method. An outside source of steam removes then all non-condensable gases 176. As set forth above, vacuum may be created using methods such as the hot fill and hold method or vacuum fill. In the preferred embodiment of FIG. 7, the hot fill and hold method is used.

[0062] The container is then sealed 178 so as to create a vacuum within the container. Then the product 30 is sealed in the container 20 using the combined stopper 24b, 24c/stiffening ring 22b, 22c. It should be noted that other apparatus could be used to seal the container 20. Eventually, the head space gas collapses 180 to water to create 182 a vacuum and/or eliminate 184 the head space in a flexible container. The deflection 186 of the bottom panel 34 of the container 20 and the combined deflectable stopper panel 44 and central ring panel 50 “stores energy” and helps increase the vacuum pressure. It should be noted, however, deflection is optional and rigid components may be used.

[0063] The cap 26 may be placed 188 on the combined stopper 24b, 24c/stiffening ring 22b, 22c prior to combination being attached to the container 20, after the combination is attached to the container 20. The cap 26 may be fused, press fitted, adhered, welded or otherwise connected to the stopper 24b, 24c. Alternate embodiments could eliminate the cap 26 or make the cap 26 and stopper 24b, 24c an integral unit.

[0064] In one preferred embodiment, when the stiffening ring 22b, 22c and stopper 24b, 24c are an integral unit, the dosing cavity 42 is positioned to be in relatively close relationship with at least one breakaway feature 48, 52. Once the stiffening ring 22b, 22c and stopper 24b, 24c are an integral unit, the combination of the central ring panel 50 and the stopper panel 44 is designed to deflect such that energy is stored when a headspace gas collapses in a container, thus creating additional potential for inhalation into a zero headspace container as the container is opened.

[0065] When the consumer opened 190 the packaging system by removing the stopper 24b, the attached central ring panel 50 (which is attached to the stopper panel 44) would also be removed 192. Because the breakaway feature 52 would be preferably positioned in relatively close relationship to the dosing cavity 42, the central ring panel 50 would first come apart near the dosing cavity 42 so as to create the strongest inhalation possible therenear. The vacuum within the container 20 is released 194 as the central ring panel 50 is removed. A dose of a precise small quantity the dosing material 62 is inhaled 196 into the container 20 by the vacuum which is released as the central ring panel 50 is removed. The opening of the closure is intuitive to the consumer; i.e., little or no training or instructions are necessary.

[0066] As mentioned above, the features of the invention may be present alone or in combination. Accordingly, embodiments that are not meant to perform a particular function may not have the elements necessary to perform that function. For example, if the dosing function was not desired, the dosing channel and dosing cavity 42 would not be necessary. Another example is if the contents of the container 20 are not meant to be eaten using a spoon, the spoon would not be included. Yet another example is that if the vacuum feature was not to be used or if there was enough deflection in the stopper panel 44, then the bottom panel 34 would not have to be flexible or, if there was enough deflection in the bottom panel 34, then the stopper panel 44 would not have to be flexible.

[0067] It should also be noted that alternate embodiments may be modified without affecting the scope of the invention. For example, the container 20 may be any size or shape. Another example is that the dosing cavity 42 and dosing channel 40 may be positioned on alternate components. Accordingly, in the structure shown and discussed herein, the dosing cavity 42 may be positioned on the stiffening ring 22 and the dosing channel 40 may be positioned on the stopper 24. Further, alternate embodiments could have the functions of the stiffening ring 22 provided by the container 20 itself. For example, the dosing channel may be on an inner surface of the lip of the container 20.

[0068] The terms and expressions that have been employed in the foregoing specification are used as terms of description and not of limitation, and are not intended to exclude equivalents of the features shown and described or portions of them. The scope of the invention is defined and limited only by the claims that follow.