EP0156893A1

EP0156893A1 - Low-cost, full-function container for food, beverages and other products

Info

Publication number: EP0156893A1
Application number: EP84903686A
Authority: EP
Inventors: Donald J. Avery
Original assignee: Individual
Current assignee: Individual
Priority date: 1983-09-15
Filing date: 1984-09-14
Publication date: 1985-10-09
Also published as: EP0156893A4; GB2156774A; WO1985001269A1; GB8512101D0; JPS60502201A

Abstract

Un conteneur bon marché à multifonction (125) possède une structure (127) de matériau composite ou de carton tubulaire en spirale ou en volute, pouvant avoir différentes formes géométriques afin de renfermer un récipient à paroi mince (131) à base d'un matériau formant une barrière pour renfermer et protéger un produit, l'épaisseur et la rigidité de la structure étant suffisantes pour soutenir et protéger au moins les côtés renfermés ainsi que le fond du récipient. L'épaisseur de la paroi en matériau du récipient ne permet pas au récipient de servir tout seul conventionnellement de conteneur pour le produit. Une fermeture (133) à l'extrémité supérieure du récipient assure l'étanchéité du produit de manière hermétique ou atmosphérique, le produit étant protégé de l'air, des autres gaz, de l'humidité et de la lumière. Le récipient peut être formé in situ à l'intérieur de la structure.An inexpensive multifunction container (125) has a structure (127) of composite material or tubular cardboard in a spiral or volute, which can have different geometric shapes in order to enclose a thin-walled container (131) based on a material forming a barrier to enclose and protect a product, the thickness and rigidity of the structure being sufficient to support and protect at least the enclosed sides as well as the bottom of the container. The thickness of the container material wall does not allow the container to conventionally serve as a container for the product by itself. A closure (133) at the upper end of the container seals the product hermetically or atmospherically, the product being protected from air, other gases, moisture and light. The container can be formed in situ inside the structure.

Description

LOW-COST, FULL.-FUNCTION CONTAINER FOR FOOD, BEVERAGES AND OTHER PRODUCTS

BACKGROUND AND SUMMARY OF THE INVENTION

This invention relates to improvements in containers for food and beverages and other products which must be packaged in a sealed condition, being especially well suited to the packaging of hermetic-packed products which are sensitive to or effected in some way by oxygen (or other gases) , moisture and/or light, including but not limited to all types of food,..beverages and other products such as those which have been heretofore hot filled, cold packed, frozen, aseptically prepared, pasteurized, retorted, high-temperature, short-time (HT-ST) packed, etc., and otherwise processed. Containers of the invention are also useful for packaging of atmosphere-packed products such as, for example, motor oil, industrial and consumer products, lotions, medicines, wet or dry chemicals, cleaners, automotive supplies, and so on. Conventional containers, whether made of metal, glass, paperboard, or of single-layer or laminated materials, including foil-lined paperboard, coated, treated or waxed materials, and including many polymers and resins, have inherent disadvantages. Among other things, conventional containers utilize too much material, sacrificing thinness for the advantage of strength. Thus, it is common to utilize metal, relatively thick glass, or polymeric or resinous materials simply to obtain the necessary stiffness, rigidity and resist¬ ance to breakage. However, maximizing structural strength maximizes the cost of materials. In the case of products

5 which must be sealed against air, other gases, and/or moisture, high barrier plastics can be utilized, but the provision of sufficient thickness for strength, utilizing such materials, increases cost and does not conserve materials. In the case of glass bottles, excellent

10. resistance against moisture and atmospheric contamination and internal pressure is provided, but at the sacrifice of great weight, to ensure againsf breakage.

Steel cans are decidedly obsolescent, having become expensive to manufacture and having always been beset

15 with functional problems. In the case of more modern cans formed of drawn aluminum, the desire to reduce the amount of material- utilized has provided cans of such thinness that they sometimes develop leakage through pinholes during the normal abrasion of filling processes.

20 Thin-walled cans are dented and damaged during physical distribution.

Although composite cans consisting of spirally or convolutely wound paperboard, including a foil or poly¬ mer lining, or foil-polymer combinations, such as pro-

25 duced by the so-called Anaconda fold process, have been utilized on a widespread basis,- they suffer also from disadvantages, including leaking. Such spiral-wound composite cans have been utilized, for example, for con¬ taining snack food, frozen concentrates, and motor oil,

30 but have been prone to buckling, collapse, development of pin holes, as well as capillary leakage or wicking. Such cans also require top and bottom seams which con¬ stitute a potential for leakage in addition to requiring material and process procedures which it would be desir-

35. able to eliminate.

Additional problems are posed by containers which contain carbonated beverages, since the internal pres¬ sure of the container when filled must be withstood by the containment vessel if rupture- is to be avoided.

Indeed, the rupture of glass soda bottles has been a widespread problem as well as a source of injury and loss to customers leading to the development of resin containers but which must be of substantial thickness and which require reinforced constructions.

There is a need for a new generationof low-cost containers capable of providing the full functions which consumers demand or expect from containers.

It is believed that the packaging industry has failed to address the needs and concerns to- which the present invention is directed; the packaging industry has developed around standardized production, concentrati on the high volume, low cost continuation of existing technologies and endeavoring to protect existing markets. Although there are a number of different packaging and material technologies, including polymers and resins, composite cans, metal containers, flexible packages, as well as glass, these are all separate bodies of know¬ ledge, materials experiences, science and art. It stands to reason, for example, that someone in the plasti container industry would not concentrate on combining plastics with other forms of packaging or materials because such has tended to pose the risk of market deterioration. There has been little concentration on materials outside a particular industry. Further, there is inherent tendency to maintain the status quo, coupled with industry-limited concerns for labor, capital, cost a foreign competition.

Accordingly, it is an object of the present inventio to combine dissimilar materials and packaging technologie to provide a low-cost, full- unction container of greatly improved- character for food, beverages and other products which must be packaged in a sealed condition, thereby to provide a container which provides improved function, structure, shape and graphics (including printing, labeling, illustrative and decorative effects) by the combination, in a novel manner, of an external

0^*vIPI ι?o ^• structure together with an internal vessel, surrounded by the structure, the vessel being of material for pro¬ viding a high barrier seal for the products to becontained.

It is an object additionally to provide such a ^*-" low-cost, full-function container which can be more easily and cheaply manufactured, and which utilizes less materials, than prior art container of comparable utility, in general constituting a more economicalpackage while performing functions as well as or better^** than

10 prior art containers.

A further object of the invention is the provision of a container of the character stated capable of utili¬ zing very thin vessels, surrounded by protective and sup¬ portive minimal thickness, being thinner than heretofore

15 recognized in the packaging industry as suitable for the containment of foods, beverages, and other products, but nevertheless having sufficient material characteristics and strength to form an adequate vessel and barrier against oxygen, other gases, moisture and light.

20 Another object of the invention is the provision of a container of the character stated which is capable of the containment of an extremely wide and diverse range of products and substances, capable of providing not only the marketer but also the consumer with a

25 variety of shapes and sizes of containers, including configurations not heretofore readily available.

A further object of the invention may be noted as being the provision of a container of such character which allows vessels to be formed by drawing of resins

30 and polymers to a deeper draw ratio than heretofore has been obtainable with existing containers, including per¬ mitting the vessels^" of the container to be produced by drawing from a flat sheet of membrane of such synthetic materials.

35 Another object of the invention is the provision of such a container having a vessel and surrounding structure which can be made byformingthevesseldirectlywithin the structure by forming or drawing of the vessel from a sheet of membrane of such synthetic material, or which can be made by preforming the vessel and then inserting it into the structure. It is an object of the invention to provide such a container which can be formed with metal or glass as ^• the vessel in a thinner wall thickness than has hereto¬ fore been obtainable economically or feasably with pre¬ viously known packaging concepts. It is an object also of the invention to provide a container of the character stated which has fewer func¬ tional pieces than has heretofore been possible.

Still another object of the invention is the pro¬ vision of such a container which allows plastics, i.e., resins and polymers, to be utilized more economically and effectively than in the past for the packaging of carbonated beverages and alcoholic beverages, including beer, food_.and other products.

Among still other objects of the invention may be noted the provision of such a container which allows more economical and more functional closures or opening fea¬ tures; and which is superior in its suitability for having graphics provided on the container; and which is more nearly biodegradable than existing synthetic con- tainers in utilizing a fully biodegradable structure and a vessel of very little substance, so that the invention will minimize the amount of waste in landfills, etc. In this regard, the invention also has as anobject the provision of a combustible product, as compared with presently used thick, incombustible materials.

Another object of the invention is the provision of an advantageously simple method of making the new con¬ tainer by the in situ formation of a vessel within a structure therefor. Other objects and features will be in part apparent and in part pointed out hereinbelow. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1 is a side elevation view of a prior art can of the drawn type.

FIGURE 2 is a vertical cross .section of a mold having a sheet of polymeric material clamped therein for being drawn into a vessel for utilization in the invention, the thickness of the material being exaggerated.

FIGURE 3 is a similar vertical cross section:_.-of the arrangement of FIGURE 2, showing a ram received within the mold during the drawing operation to produce a drawn vessel, also with material thickness exaggerated.

FIGURE 4 is a partial vertical cross section of a mold arrangement, including portions of a ram, with a flat sheet of material being shown, with exaggerated thickness, in position for being drawn and formed iri situ within a structural member of the invention.

FIGURE 5 is a similar vertical cross section illus-f_._rati.--_g the vessel as so formed in situ within the structure provided in FIGURE 4. FIGURE 6 is a perspective view of a vessel for utilization in providing a- container in accordance with and embodying the present invention, the material thickness being exaggerated.

FIGURE 7 is a similar perspective view of a structural member, or so-called structure, partly broken away, for utilization in the new container.

FIGURE 8 is a similar perspective view of the container comprised of the structure and vessel of FIGURES 7 and 8, with portions thereof being broken away for illustration. Thickness of materials is exaggerated. FIGURES^'9A - 9C are fragmentary cross sectional ill-ustrations, with thicknesses being exaggerated, of polymeric constructions utilized for vessel portion of containers of the present invention. FIGURES 10, 11 a-d 12 are, respectively, a top plan view, side elevation, and vertical cross section of one form of vessel of the invention.

_ O ^■ FIGURES 13, 14 and 15 are similar views of another possible form of vessel of the invention,

FIGURES 16, 17^' and 18 are similar- iews of yet another possi¬ ble form of vessel of the invention.

FIGURE 19 is a perspective view of a triangular-form container of the invention, with both the structure and vessel thereof being partly broken away for illustration.

FIGURE 20 is a perspective view of a beverage container in accordance with the invention, with the structure being partlybroken away for showing the presence of the vessel therein; its material thickness being exaggerated.

FIGURE 21 is a fragmentary vertical, cross section of a con¬ tainer in accordance with the invention,, showing one form of closure, material thicknesses being exaggerated. FIGURE 22 is a cαriparable vertical cross section of another container in accordance with the invention, showing yet another closure secured to the container, by double-seamed seal as well as illustrating the securement of the vessel within the structure, material thickness being exaggerated, FIGURES 23A and 24B are fragmentary-vertical cross sections, also with thicknesses being exaggerated, showing two other forms of container of the invention and closures therefor, as with a single or double seam heat-seal or ultrasonic seal.

FIGURE 24 is a side elevation view of a food, beverage, or other products container .in accordance with the invention.

FIGURE 25 is a vertical cross section, as taken generally along line 25—25 of FIGURE 24, showing with exaggerated material thickness the structure, vessel and closure features of the con¬ tainer of FIGURE 24.

FIGURE 26 is a side elevation view of yet another containerin accordance with the invention but employing a glass or plastic vessel and its closure.

FIGURE 27A is a vertical cross-section, as taken generally along line 27—27 of FIGURE 26, and showing the securement of the glass or plastic vessel within the structure, as well as the closure, which is of the screw-on or roll-on type; and FIGURE 27B shows a plastic or glass vessel variant,-

OMPI FIGURE 28 is a side elevation view of another form of container of the invention, wherein the vessel protrudes above the structure.

FIGURE 29 is a vertical cross section of the container of FIGURE 28, the thicknesses being exaggerated, as taken generally along the line 29—29 thereof.

FIGURE 30 is a side elevation view of a bottle-form container constructed in accordance with and embodying the present invention. FIGURE 31 is a vertical cross section, partly broken away, of the container of FIGURE 30, as taken generally along line 31—31 thereof.

FIGURE 32 is a fragmentary vertical cross section of a similar container but with the vessel being differently formed and integral with the top of the container, also with thicknesses being exaggerated.

FIGURE 33 is a side elevation view of an alternate form of container of the invention including two vessels therein and closures on opposite ends of the container.

FIGURE 34 is a vertical cross section taken generally along line 34—34 of FIGURE 33, with material thicknesses being exaggerated, illustrating the provision of the double vessels therein. Throughout the several views of the drawings, none are necessarily to scale or are accurately representative of material thicknesses.

DESCRIPTION OF THE PREFERRED EMBODIMENT Background

Referring to FIGURE 1, there is generally illustrated a drawn can of the prior art and constituting just one of many conventional containers for foods, beverages and other semi-solid or liquid products wherein the container must serve primarily a dual function of not only protecting the contents, but also providing a. package of sufficient structural rigidity and strength that ordinary handling of the can during filling, physical distribution, commerce, and ultimately by the consumer will not cause the can or container to dent, distort, rupture or leak its contents. In many ways, can 1 represents the state-of-art in the container packaging-industry, where the incentive to reduce the cost of materials is restricted by certain approaching design limitations. Thus,^' with a can of such configuration, drawn of thin aluminum to provide a closed bottom end 3 and having a closure 5 across its .upper end including a body wall beaded as at 7, the thinness of the material has reached the point where even through the abrasion of normal filling and packaging operations, pinholes may • develop through which leakage may occur. Also, the side walls 9 are of such thinness that they may easily be collapsed or crushed, or otherwise damaged, resulting in an unsightly denting or- rupturing of the can, during normal handling. Therefore, it may be said that for sucn existing packages or containers, wherein there is a combination of both the structural and containment functions in a single entity or single materials technology, a limiting stage in the evolution of such containers has been reached.

Brief Summary of the Invention

The invention provides a low-cost, full-function container which differs from standard, typical or conventional containers, making use of different technologies', materials, and combination of ^• separate pieces, to accomplish the several functions requisite for containers. A container of the invention broadly Comprises a-thi

constituting a barrier for enclosing and protecting a product; the wall thickness of the vessel is inadequate for permitting it to serve conventionally alone in nor¬ mal use, i. e. , as a standard or typical container for the product. Such material is selected from the group consisting of polymers and resins , thin metals , and thin glass . Separately, there is provided a structure of con¬ volute or spiral wound paperboard herein defined as also including paperboard, foil. and/or paperboard-polymer com- posites , of sufficient thickness and rigidity for at- least partially enclosing the vessel to support and pro¬ tect at least the sides and bottom of the vessel. Finally, a closure- is utilized for closing the vessel at least at one end and for sealant the product atmospherically or hermetically within the vessel, whereby the product is contained under conditions protecting it from air , other gases , moisture and light. Basic Construction Referring now to FIGURES 6-8 , reference numerals 11 , 13 and 15 , respectively , indicate a new container in accordance with the invention , the so-called structure , and the vessel which is enclosed by the structure . In this example, vessel 15 is formed of a so-called tub or cup configuration having either a flat or upwardly con- vex floor 17 , straight or tapered sidewalls 19 and a peripheral flange 21 which extends radially outwardly from an enlarged diameter portion 23 defining a de-nest¬ ing ring or ledge 25. Vessel 15 may be transparent, translucent or opaque. It is received within structure 13, which is formed of paperboard wound by the use of cαimercially available convolute or spiral winding technology, being thereby opaque and the paperboard being of sufficient thickness and rigidity for supporting and protecting at least the sides and bottom of vessel 15. The shapes of the vessel and structure may be of various geometric configurations. Tubular structures are most pre¬ ferred. In the tubular form shown, structure 13 has vertical side¬ walls 27 having at the bottom to provide an inwardly-directed curl or roll 29 and tapered outwardly slightly at the upper margin 31, upon which de-nesting ring 25 is seated. Thus, the vessel

^' - ^• is contained within the structure so that the enlarged diameter portion 23 extends above the structure. The structure, open at its lower end, is of sufficient height so that a space^' exists between a surface upon which con- 5 tainer 11 is seated and the floor 17,

Although not shown, a film of resin, polymer, foil, paper, or a composite of these materials (herein, "com¬ posite") may be used to close the open lower end of the structure, as for reasons of protection for the vessel, 10^* appearance, and cosmetics.

Although not shown, it is preferred that a layer of adhesive, bonding substance or polymer-film be provided between the interior surfaces 33 of structure 13 and the outer walls 19 of vessel 15 in order to bond or adhere 15 the structure and vessel together in integral relation¬ ship. Other means may be utilized for securing the structure and vessel together in integral relationship. Materials of Construction

A wide range of materials are available for con¬

20 struction of vessels of the invention, including resil¬ ient resins and polymers as well as thin metals and glass . Most preferred are the polymeric high barrier materials providing a sufficient barrier against the movement of oxygen, other gases, moisture and light across the barrier, even

²⁵ with extremely small thickness. Greatly preferred barrier materials are the saran resins. The generic term "saran" represents a series of vinylidene chloride copolymers with, e.g. , vinyl chloride or acrylates and methacrylates , and styrene . The term saran includes generally such vinylidene chloride copolymers as

-*^■ *- well as polyvinylidene chloride ; the properties of a saran include inertness to common acids and alkalies , the com¬ plete resistance to water during immersion, negligible water vapor transmission, toughness , and durability , being available in sheet and films which can be formed into

³⁵ vessels of the present invention. Also, the polymeric coextruded or laminated sheet and films available commercially under the designation "EVAL", being a class of ethyl vinyl alc¬ ohol polymers or copolymers, are of extreme interest in providing high barrier capabilities usable for the pres¬ ent vessels. Also useful are a group of ionomeric res- ins available under .the trade designation "Surlyn", which are thermoplastically formable. Other synthetic polymers may be used depending upon the strength required and the need for a barrier, and such materials include high den¬ sity polyethylene (HDPE) , ultra high molecular weight polyethylene (UHMWPE) , polypropylene (PP) , high impact polystyrene (HIPS) and general purpose polystyrene (GPPS) as well as styreneacrylonitrile (SAN) , acrylonitrile butadiene-styrene (ABS) , the high nitrile barrier resins, "BAREX" polymer and polyethylene terephtalate (PET and PETG) . The high barrier materials such as the sarans and EVAL may be combined with mono-layers of other low bar¬ rier materials, such as low density polyethylene (LDPE) , HDPE, PP, and HIPS, to advantage in constructing vessels of the invention with good physical properties, including resilience, toughness and strength in spite of thinover¬ all material thickness.

Metals may also be used, especially drawn steel or aluminum of very thin thickness and foil-like nature, including polymer-coated metals or foils. Since enclsoed poritons of vessels of the invention are not primarily required to exhibit strength, being protected by the structure, they need not be stiffly resilient but may be of flexible plastics, as well as flexible or paper-laminated materials, and particularly of a coated nature.

It is contemplated also that glass may be utilized for vessels of the invention but with much less thick¬ ness than has been heretofore possible for glass contain¬ ers; the glass may be coated with suchpolymers and resins. Methods and Details of Construction

With respect particularly to the use of plastics for the formation of a vessel of the invention, attention is directed to FIGURES 2 and 3, illustrating .the use of a technique known as the scrapless forming ,process (SFP) for making vessels., The process makes use of a mold 35 in which a preform 37 is clamped between lip rings 39, 41 for being pressed into mold cavity 43, to which vents 45 provide communication with a vacuum source for assisting drawing of the preform into the mold cavity. An assist plug or die 47 aids formation of the preform 37 into an initially formed vessel 37', pressure being provided through a vent 49 for assisting in the drawing into the mold cavity 43. The lip rings 39, 41 form the peripheral configuration or rim of the shaped article 37' upon closure of the lip ring, which may be colled, whereas the inner portion of the preform is maintained at an elevated temperature prior to being drawn, such as from 230°F to 280°F. The mold 35 is itself cooled so that the article will retain its shape when the draw is complete, as in FIGURE 3.

Although thus-formed vessels used for prior art containers typically might exhibit an average wall thickness of up to 60 mils or more, wall thickness of vessels such as the tub or cup 37' formed in FIGURE 3 to be^' utilized in constructing a container of the present invention will be far thinner, as from about 1 to about 20 mils, or possibly up to about.-.30 mils for large containers, enabling the draw ratio,-, i.e.-, the ratio of the diameter of the drawn article to its height, to be much greater than previously obtainable. Conventionally, it has been common practice to-use a draw ratio of up to 1:1.5, with the deepest draws obtainable being from about l:1.5^'tol:2, but thin wall vessels of the present invention allow draws to ratios of up to 1:3 or 1:4. Thus, very deep vessels can be constructed by the use of the forming process described above.

The vessels can also be made by solid-phase pressure forming of such resins or polymers, or by thermoforming, the SFP process being illustrative only of one forming method.

Referring to FIGURE 4, there is illustrated a novel method of in situ formation of a vessel 52 within a structure 51 of the invention. Structure 51 is retained within a mold 53, whereby the interior 55 of the struc- ture becomes the mold cavity for forming therein of the vessel from a hot sheet 57 of the desired polymer by deforming it by an assist .plug or plunger 59. A cutting knife 61 may be utilized to trim a sheet or filmof mater¬ ial 57 to its desired dimensions before or as the plug 59 i_s pressed downward. In FIGURE 5, the ram or plug 59 has moved down, forcing the sheet 57 into a formed vessel 57' while a lip.ring 63 retains and forms the flange 65 of the thus-formed vessel. The mold may be relieved, as at 6.7 to provide space for receiving a body curl 68 of the structure. Although not shown, a layer of adhesive, bon-^' ding substance, resin or polymer film may be provided wihtin the space 68 between the vessel 57' and structure 51 for bonding the two together in integral relationship. In FIGURE 9A, the construction of vessel material i_s illustrated, there being a relatively thick layer 69 representing the structural material of the container and a very thin polymeric layer 71- representing such portion of the vessel as is contained within and/or bon¬ ded to the structural material by a thin adhesive coat- i_ng or adhesive layer 73 of adhesive bonding material of a suitable conventional type, such as a thermally acti¬ vated type. Additionally, a film of resin or polymeric material, e.g., those- of thermoplastic type, may be utilized for the adhering layer. The thickness of layer 71 is here exaggerated, being within the generally pre¬ ferred range of from about 0.0005 to 0.030 in. or, more specifically preferred, in the range of from about 0.001 to about 0.020 in.

Portions of the vessel which extend above the structure and are accordingly unprotected may, if formed of such polymeric materials, have a total wall thickness of up to about 0.040 in., as may be necessary especially for large containers.

In FIGURE 9B, layer 71 is shown with even more exaggerated thickness according to one possible con¬ struction of a multi-layer, extruded laminated form, which can be used. Thus, there is provided a layer 75 of PS, PE, or. PP, the thickness of which may be, for example, 0.010 in, Similarly, a layer 77 of one of such materials may also be on the^' opposite side and of comparable dimensions, there being a barrier layer 79 between layers 75 and 77 and tied to them by tie or adhesive layers 81, 83 of little thickness.

The barrier layer 79 may be as little as 0.0001 in_. but, more preferrably, at least 0.0005 in. and, thus, of material such as EVAL or a saran or "Surlyn". However, the thickness of layer 79 may be increased up to as much as about 0.004 in. but preferrably not more than about 0.002 in., while the thickness or the ca layers 75, 77 may diminish to zero.. The so-called tie layers may be of a thermoset adhesive as has heretofore been utilized for the typing together of such co-extruded or laminated materials.

In FIGURE 9C, a multilayer form of vessel material is illustrated, as produced by co-extrusion, there being representatively shown an outer (structure-adjacent layer 84a, as of PP or PE, a barrier layer 84b, as of EVAL, and an inner layer 84c, as of PP. • Other multiple layer constructions are also possible.

Structures of the invention are formed most preferra by use of convolute or spiral wound paperboard methodolog of existing single-ply or multi-ply type using simple paperboard or what are herein termed composite materials including paperboard backed with or bonded to foil, resins and polymers, including the previously mentioned "Surlyn". The adhesive layer may be carried by structure and caused to bond or adhere to the vessel only after insertion of the vessel within the structure, as by heat treating. The structures may be externally or internally finished with various polymers or wax coatings, and the bottom end or both ends may be further treated or dip-coa - A - to prevent moisture from degrading such end or ends and for additional stiffening. Such structures are well- suited for labeling or printing of graphics directly on their outer surfaces, such as multicolored designs and text. Further, the structures may be manufactured with designed material coloration. The structures also may be apertured for decorative purposes or textured effect, and may have smooth or rough surfaces as desired. Typical material thickness for sidewalls of structure of the invention, as used for containers of up to two- liter capacity, preferrably may be within the range of about 0.020 in^", to about 0.080 in.

- 16 - The following examples illustrate the invention:

EXAMPLE I Referring to -FIGURES 10-12, a container of the invention may be rectangular, being provided with a vessel 85 having a flat bottom 87 from which slope inwardly a flat lip or flange 91 extends horizontally outwardly from the upper ends upon the upper edges of the walls thereby providing a surfaceto-which a foil, polymer, foil/polymer or coated paper closure may be readily adhered by heat sealing or ultrasonic bonding. The lip 91 also serves to support the vessel within a suitable structure of the type hereinabove described. High barrier materials including a saran or EVAL may be used for vessel 85, and it may be molded or drawn of a laminated form or co-extruded multiple-layer material as shown in FIGURE 9B. The configuration is well suited for certain food products such as sauces, entrees, snacks and the like-. The vessel 85 alternatively may be of thin metal such as aluminum or steel. EXAMPLE II

Referring to FIGURES 13-15, a vessel 93 of the inven¬ tion may be molded, formed or drawn of circular shape and cup or tub-like configuration, having an upwardly convex bottom 95, from which elope outwardly a flat sidewall 97 having at its upper end a relatively wide outwardly- directed horizontal flange 99. Vessel 93 may be formed of a polymeric or resinous material as previously described, and may be molded, formed or drawn. Very thin-section aluminum or steel may also be used. EXAMPLE III

Referring to FIGURES 16-18, a vessel 101 of the invention is of oval or elliptical shape, having a flat bottom 103 from- which extend vertically upward a single sidewall 105 provided at its upper end with an outwardly directed horizontal flange 107. There may be used one of the various polymers or resins previously indicated, pigmented, or not as desired, and transparent, trans¬ lucent or opaque as dependent upon the need to block light from the contents. Aluminum or steel of very thin, cross-

U

O section may be used, such as from about 0.001 in. to about 0.010 in. .in thickness, such as will be less than the thinness drawn al^*__^*ιinum cans of approximately 13 mils thickness,

EXAMPLE IV Referring to FIGURE 19, a container 109 is of tri¬ angular shape; having a vessel 110 with a flat floor 113, from which the sidewalls 115 extend upwardly and in slightly outwardly diverging relationship to a horizon¬ tal flange 111. Surrounding the walls and of slightly greater height is an opague paperboard or composite material structure 117 having vertical side walls, as at 119, which terminate in an inwardly directed roll 121 at the lower edge. Each such side wall 119 of the tubular structure 117 has a slightly outwardly tapered portion 119^r at its upper end for tight conformance with the vessel sidewall 115. Adhesive bonding substance 123 of suitable type is provided between the vessel and struc¬ ture, being coextensive with at least the upper one-half and preferrably slightly more of the side wall extent for bonding the structure 117 to vessel 110 in integral relationship.

EXAMPLE V Referring to FIGURES 20-22, a container 125 of the invention is used for containing a carbonated beverage such as beer. It includes a cylindrical, tubular struc- ture 127 similarly of convolute or spiral wound paper¬ board or composite construction as previously described, which is provided at its lower edge with a roll 129. The bottom of such structure 125 is open but may instead be closed with a thin layer suchas polymer film, forreasons of protecting the vessel or appearance. Contained within the structure 125 is a vessel 131 of the previously described type of preferred synthetic material, e.g., a polymer or resin, such as of the laminated cross-section shown in FIGURE 9B, including a barrier layer 79. The vessel may instead be of thinly drawn steel or aluminum. The container is closed at its upper end with an aluminum or steel closure 133 forming with the vessel and structure 125 a single- seam crimp or double-seam crimp or periphery 135. A conventional pull tab opener 137 is provided for easy opening of the

- 8 - can . Referring to FIGURE 21 , the container is shown by fragmentary view before the seamed or crimped seal 135 is provided. The side wall of the vessel 131 is desig¬ nated 139 , being provided at its upper extent with a slight flair or nesting ledge 141 , a further nearly upright but slightly outwardly directed extension 143 and a radial outstanding flange 145 , Similarly , struc¬ ture wall 127 is provided with a nesting ring or body bead 147 and an outwardly directed, horizontal flange 0 149 which is parallel to and supports the vessel flange 145 . Closure 133 is similarly provided with an out¬ wardly oriented horizontal flange 151 having a slightly downwardly turned portion 151 '^' exteriorly of the periph¬ ery of flanges 145 , 159. For completion of assembly , ^*-¹ flange 151 and its outward extent 151 * are rolled tightly about structure flange 149 and vessel flange 145 to provide the single or double-seamed seal 135. A lowermost region of structure 125 is wax coated or otherwise treated with a polymer coating to waterproof 0 it and prevent the roll 129 from wicking up moisture or becoming deformed. Such region is designated at 153 . It will be further observed that the bottom 155 of vessel 131 is upwardly convex for permitting outward expansion , that is , flexing , in response to internal pressure generated by carbonated beverages such as soda and beer . High internal pressure is possible with such _^ a container. An adhering layer of adhesive , bonding substance , or resin or polymer film 157 is provided between the upper half of the vessel 131 and structure 125 for bonding the two together .

EXAMPLE VI Referring to FIGURE 23A, vessel 131 is of very thinly drawn aluminum or steel or polymer, for example, and has a metal closure which is single- or double-seam sealed to a necked-in shoulder 134 of the vessel. Structure 127 of the previously-described construc¬ tion, terminates at shoulder 134, exposing only a small amount of the vessel. The vessel is necked-in and has a metal easy-open clo¬ sure similar to existing beverage containers. Referring to FIGURE 23B, an alternate closure variation is illustrated, providing what

- - is termed as easy-open C"EZ-Open") membrane style clo¬ sure 133 as of polymer coated aluminum foil or coex- truded high barrier materials, as in FIGURES 9A-9C. Closure 133 has a portion 151 bonded as by heat-sealing or ultrasonic bonding to a corresponding flange 145 of vessel 131, the structure 125 having a slightly flanged or tapered upper extent 159 upon which a de-nesting ledge 161 of vessel 125 is seated. Adhesive or other bonding substance 157 bonds the structure 125 to vessel 131. Closure 133 is easily peeled away from flange 151 for opening as by a tab 133*.

EXAMPLE VII Referring now to FIGURES 24 and 25, there is illus¬ trated a container 163 of the general type formed, for example, by the process of FIGURE 5, wherein there is provided a structure 165 of convolute or spiral wound paperboard of cylindrical tub lar configuration, having at its lower end an outwardly folded curl 167. A radial outwardly-directed flange may instead be provided. The vessel 169 has its bottom 170 spaced well above the bottom edge. Here, the upper end 171 of the structure ends abruptly without a roll or flange, but the vessel is provided with a- downwardly turned lip 172 for receiv¬ ing said upper portion 171, there being adhesive 173 throughout the upper half of the container between the structure and vessel and with such adhesive lapping over and around the upper end 171 of the structure. Accord¬ ingly, there is provided a well-defined, smooth upper periphery of the vessel for receiving a closure 175 such as may include a curled periphery 177 for providing an easy-pull or snap-on relationship with lip 173. Closure 175 may be of various materials, including aluminum, foil/polymer film, "Surlyn" film, coated paper, foil, and synthetic coextruded high-barrier substances and combin- ations (as in FIGURES 9A-9C) . The downfolded lip 172 of the vessel provides a clean, hygienic surface, having been covered by the closure periphery 177, as will be attractive to the consumer, especially for consumption of beverages directly from the container 163. For con-

- - taining beverages generating internal pressure or vacuum within the vessel 169, the bottom is provided with an upwardly convex portion 179. If vessel 169 is of drawn aluminum or steel, it may have a wall thickness of preferrably from about 0.001 in. to about 0.015 in. Alternatively, a foil-polymer com¬ bination material may be used for vessel 169; and such material may be heat sealed within structure 163, providing thermal acti¬ vation of adhesive 173, The interior of structure 165 may be precoated with adhesive' as by roll-on or spray coating prior to the vessel being placed within and adhered to the structure,

EXAMPLE VIII Referring to FIGURES 26 and 27A, a container 181 of the invention is provided with a structure 183 having a necked-in or beaded portion 185. Structure 183 is provided at its lower edge with an inwardly turned roll 187, the- structure being open and providing a recess 189 below a vessel 191. . As shown, the vessel may be of thin glass or plastic, being provided also witha necked- in region 187 for conformance with the neck 185 of the structure, thereby providing a means for securing the structure and vessel together in integral relationship. A lip 193 is formed at the upper end of the vessel, being turned down to define a recess within the lip for receiving the upper end of the structure. A layer of adhesive 194 may be provided between the vessel and structure for bonding them together, or the bonding or locking together of the structure and vessel may be provided by means of the mutually configured necked regions 185, 187 of the respective structure and vessel. Threads as. at 195 may be formed on neck 193 for receiving a screw-on or roll-on closure or cap 197, which may be of metal, polymer, or polymer-coated metal. The thickness of vessel 191 in the region of its lip 193 may be increased relative to that in the side walls, as at 199 to provide greater strength in the region of closure 197. In those regions of the vessel contained within the structure, the vessel wall thickness may be from about 0.002 in. to about 0.020 in. for a container capacity ranging between about 4 oz. to about 64 oz. In lieu of glass or plastic, vessel 191 may be formed of drawn aluminum, steel or other thin composite materials, including a single layer or multiple layer polymers of the type previously described, but in any event, being by itself of insufficient thickness to serve alone as a standard or typical container, requiring the structure 183 for requisite strength and protection of the vessel. Referring to FIGURE 27B, container 181 may have its vessel 191 of thin glass, metal resin or polymer mater- ial of single or multi-layer type described hereinabove, and secured by the adhering layer 194 within structure 183, which terminates below the top of the vessel. The exposed vessel portion has its upper margin threaded as at 195 for receiving screw-on or roll-on closure 197. EXAMPLE IX

A further variation of a container of the invention is designated at 201 in FIGURES 28 and 29. Said contain¬ er is provided by a tubular structure 203 of convolute- or spiral wound paperboard, being, for example, but not necessarily, of cylindrical form and provided at its upper end with a horizontal radial flange 205, and at its lower end with an inwardly-turned roll 206. Within structure^"203, . there is provided a vessel generally des¬ ignated 207 but having- a lower portion 209 and an upper portion 211 of different configurations. The lower por¬ tion has a flat bottom 213 (which may instead beupwardly convex) and from which there extends with a slight taper upwardly side walls 215 which conform closely to the inner surface of said structure 203. A layer of suit- able adhering or bonding material of layer 217 is pro¬ vided throughout the upper half of said portion 209 for bonding it to the interior of structure 203. The adhes¬ ive is provided also across the top of lip or flange 205. Upper portion 211 is- of upwardly diverging or tapered cup-shaped configuration and of larger diameter than the lower portion 209, being provided with a seat or flange 213 for seating upon the structure flange 205. and being

bonded to it by the adhesive. An external roll, flange or bead 219 is provided at the upper end of portion 211 for receiving a snap-on, seamed-on or membrane closure or cap 221, which may be of metal, foil, plastic or com- binations of metal, plastic and foil. The lid, which is of larger diameter than upper vessel portion 211, has a lip 223 for snapping over curl 219. Closure 221 may be instead of a membrane type and may be of snap-on type as shown or instead sealed suitably as by heat-sealing or ultrasonic bonding. Single or double-seamed sealing may also be used. Although the wall thickness of vessel 207 is shown to be constant, the upper lower portion 211 may be of greater material thickness than the lower portion 209 since it is not fully enclosed and protectedby struc- ture 203. Container 201 is particularly well-suited for beverages of a carbonated or non-carbonated character, being easily grasped by the reduced diameter aspect of its lower portion whereas the upper portion 211 of the vessel diverges into a cup-like configuration exposing large extent of the vessel material for contrasting appearance or to provide an attractive clean surface for drinking. Vessel 207 may be formed of a single layer polymer or multiple layer polymers of the type previous¬ ly described, but less preferrably may be formed also of drawn aluminum steel or other thin materials, previously identified. Container 201 may be of a size from a few ounces to substantially more, such as, e.g., about 16 ounces. Alternatively, container 201 may be formed with an "EZ-Open" membrane closure of the type shown in FIGURE 23, with polymer-coated foil heat-sealed to the vessel.

EXAMPLE X Referring to FIGURES 30 and 31, a further container 225 of. the invention is well suited to the containment of relatively large volumes of liquid, such.as one or two liters being thereby of size heretofore utilized for carbonated soda beverages. Container 225 includes com¬ posite, convolute or spiral wound paperboard structure 227 of cylindrical or other geometric configuration, being provided with a relatively large, heavy-duty outwardly- directed roll 229 at its lower end but open to provide protective space 231 below the vessel, which is designated generally 233. Vessel 233 is provided with upwarldly convex bottom 235 and from which extend upwardly with a slight outward taper side walls 237 for being secured within the structure by a layer of adhesive 239 throughout the upper half of the structure. As- in the previous example, there are two portions of vessel 233, a lower portion 241 contained almost fully within structure 227, and an exposed dome-shaped upper portion 243. In the example shown in FIGURES 30 and 31, the upper portion 243 is separate from the lower portion 241, being provided with an enlarged diameter collar or flared ^• portion 245 for being received upon a downwardly turned lip 247 of the lower portion, and secured thereto as by heat-sealing,ultrasonic bonding or spin-welding. Portion

243 may be of relatively greater thickness than the lower portion 241, which is of a material thickness insufficient for serving by itself as a container in normal usage. At the upper 'end of said upper portion 243 is a spout or neck 245 which is threaded, as at 247, for receiving a small conventional screw-on cap of the type used for prior art carbonated beverage containers of comparable size and configuration.

EXAMPLE XI With reference to FIGURE 32, a variant of container 225 is designated ^*225 ' , being provided with its upper portion 243 in integral relationship with the lower portion 241. In this variant, the structure 227 is provided with a flange or slight taper 229 at its upper periphery upon which is seated a sloping portion 249 of the vessel demarcating the lower portion 241 and relatively larger diameter upper portion 243. Again, by proper control of the thickness of the .material of vessel, the upper portion 243 of variant 225' may be of greater strength than the enclosed lower portion 241. The vessel

O - - may be formed either of a single layer or preferrably a multiple layer of polymeric material of the type previ¬ ously described. Structure 227 is of convolute or spi¬ ral wound paperboard or composite material, the lower end of which within a region 249 is provided with a coating of wax or water impervious material, such as a spray-on or dip-applied polymer, for moisture protection and to prevent wicking or deformation of the curl 229.

EXAMPLE XII Referring to FIGURES 33 and 34, a container 249 of the invention is provided in which there are two separate vessels 251a and 251b serving as upper and lower compart¬ ment and dip in another, or for containing other separate but related comestibles, or any of a variety of other products which are often sold together but which must be kept separate for one reason or another, A necked or beaded structure 253 of rolled paperboard or composite construction of convolute or spiral wound construction •is provided. Also, a cylindrical tubular configuration is provided. However, non-cylindrical tubular configur¬ ations of various other geometric configurations could instead be employed. The structure is refolded backupon itself outwardly at its upper and lower ends, as at 255a, 255b to provide separate beads for receiving correspond- ing refolded lips 257a, 257b of the vessels. Layers of adhesive or bonding substance 259a, 259b between the vessels and structure bond the units together as a single, integral assembly. Snap-on membrane type "EZ-Open" upper and lower closures 261a, 261b are utilized, each having an under turned flange or lip 263a, 263b for extending around and under the corresponding lip 257a, 257b of each vessel to provide a snap-on easily removedrelation¬ ship. The construction lends itself to the use of "EZ- Open" membrane closures of the type previously described

€^**- - 25 - herein using a foil, polymer/foil, or composite membrane construction. Vessels 251a, 251b may be formed of single or multiple layer polymers or composite materials of the type previously described, or may instead be formed of metal, foil, drawn steel or aluminum or glass, but always being of material thickness which by itself is incapable of providing a suitable container apart from structure 253. Provision may be made for permitting the vessels.tobe separated from another, with or without being removed from corresponding structure, as for separate servings..

Accordingly, it is seen by the examples that the invention lends itself to the construction of advantageous containers having vessels and structures in many different geometries, as well as being useful for receiving closures of numerous types and materials. Such containers may be used for either hermetic or atmospheric packing of.-.a wide variety of foods, beverages, substances and products. Vessels and structures of the invention make a strong and secure container being bonded together by adhesives, bonding substances, films or heat sealing substances.

Although the foregoing includes a description of the best mode contemplated for carrying out the invention, various modifications are contemplated. As various modifications could be made in the ^"constructions herein described and illustrated without departing from the scope of the invention, it is interided that all matter contained in the foregoing description r shown in the accompanying drawings shall be interpreted as illustrative rather than limiting.

"gURE4

OMPI

Claims

. WHAT IS CLAIMED IS:

1. A low-cost, full function conta^er, cαtiprising a thin- walled vessel of material constituting a barrier for enclosing and protecting a product, a structure of sufficient thickness and rig-

5 idity for at least partially enclosing the vessel to support and protectthe sides and bottom of the vessel, the wall thickness of the vessel portions enclosed by the structure being inadequate for pei-mitt-Lng the vessel conventionally to serve alone as a con¬ tainer for such product, and a closure for closing the vessel, the

10 closure sealing the product hermetically or ai-mospherically within the vessel, whereby the product is contained under conditions protecting it from air, other gases, moisture and light.

2. A container as set forth in Claim 1 where-ln said vessel is selected frxan the group consisting of polymers and resins,

15 metal, and glass, said structure being constituted of convolute or spiral v^*ound paperboard or coitposite material.

3. A container as set forth in Claim 2 and further compris- .ing an adhering layer of adhesive bonding substance or film mater¬ ial between said structure and vessel for adhering the structure

20 and vessel together -Ln integral relationship.

4. A container as ^■set orth in Claim 3 wh≤rein said adhering adhesive is provided bewteen the structure and vessel only over an upper portion of the structure and vessel.

5. A container as set forth in Claim 1 wherein said struc- 25 ture is tubular in character and is constituted of convolute or spiral wound paperboard, or ccmposite material, the structure being open at the bottom and having an upper end fitting closure around the vessel, there being a portion of the vessel extending above the upper end of the structure, the closure being secured to such '30 upper portion. ^■

6. A container as set forth in Claim 5, the structure fur¬ ther cαnprising a curl or flange at at least its lower end, there being a space within the container below the vessel, the curl or flange being an inwardly or outwardly extending peripheral edge

35 of the structure.

OMP ^{" ■} - 27 -

7. A container as set forth in Claim 5, the vessel forming a flange above the structure, the closure being secured, to the vessel by means of such flange.

8. A container as set forth in Claim 7 wherein the closure is metal and forms with the flange a hermetic seam

9. A container as set forth in Claim 1 wherein the vessel is constituted of a resilient polymer or resin, the vessel having a bottom which is upwardly .convex for flexing in response to the pressure or vacuum internally of the vessel, there being a space within the container below the bottom of the vessel within the container.

10. A container as set forth in Claim 2 wherein both - the vessel and the structure have at least one mutually coextensive necked-in region extending annularly around the respective structure or vessel.

11. A container as set forth in Claim 1, the vessel having a lower portion within and enclosed by the structur and an upper portion extending above the upper end of the structure, the vessel being constituted of a polymer or resin material-or glass.

12. A container as set forth in Claim 11 wherein the vessel upper portion extends laterally beyond the upper end of the structure.

13. A container as set forth in Claim 12 wherein the vessel upper portion defines a ledge supported by an upper periphery of the structure.

14. The container as set forth in Claim 11 wherein th vessel upper portion is cup-shaped, the closure being of larger diameter than the vessel upper portion, the vessel upper portion being of greater diameter than the vessel lower portion.

15. A container as set forth in Claim 11, the vessel upper portion being dome-shaped and defining a threaded neck, the closure being of screw-on or rolled-on type for being received upon the neck. - 28 -

16. A container as set forth in Claim 11 wherein th vessel upper portion is a separate piece from the vessel lower portion and is spin-welded or heat-sealed or ultrasoniσally bonded to the lower portion in integral relationship.

17. A container as set forth in Claim 11, the material thickness of the vessel upper portion being greater than the material thickness of the vessel lower portion.

18. A container as set forth in Claim 2, there bein two such vessels within a single structure.

19. A container as set forth in Claim 18, the two vessels being in over-and-under relationship for opening from opposite ends of the structure, there being separate closures for each such vessel.

20. A container as set forth in Claim 1 wherein the vessel is constituted of a polymer or resin and defines a high moisture, oxygen and other gas barrier layer selected from the group consisting of EVAL, the sarans, and "Surlyn", the structure being formed of opaque convolute or spiral wound paperboard or composite materia

21. A container as set forth in Claim 20, the overall thickness of the vessel material being from about 0.001 in. to about 0.030 in.

22. A container as set forth in Claim 21, the vessel material being of coextruded laminate form, said barrier layer bieng bonded to at least a forming or carrie layer by a tie layer on at least one side of the barrier layer.

OMPI - - 23. A low-cost, full-function container, compris¬ ing a thin-walled vessel of material selected from the group consisting of resins and polymers constituting a barrier for enclosing and protecting a product, the mater- ial providing a moisture, oxygen and other gas barrier thickness of from about .001 in. to about 0.004 in., the wall thickness of the vessel being inadequate for per¬ mitting the vessel conventionally to serv alone as a container for such a product, a tubular structure of opaque convolute or spiral-wound paperboard or composite material of sufficient thickness and rigidity for at least partially enclosing the vessel to support and pro¬ tect at least partially enclosing the vessel to support and protect at least the sides and bottom of the vessel, the structure having at least a curl or flange at its upper or lower end, an adhering layer of adhesive, bond¬ ing material, resin or polymer material between portions of the structure and vessel together in integral rela¬ tionship, at least a merginal portion of an upper end of the vessel extending above the structure, and a closure for closing the upper end of the vessel to seal the pro¬ duct hermetically or atmospherically within the vessel, whereby the product is contained under conditions pro¬ tecting it from air, other gases, moisture and light. 24. A container as set forth in Claim 23, said barrier layer being selected from the group consisting of EVAL,^' the. sarans -and "Surlyn", the overall material thickness of the vessel material enclosed by the struc¬ ture being from about 0.001 in- to about 0.030 in.

OMPI - 30 - 25. A method of forming a low-cost, full-function container comprising providing a tubular structure of convolute or spiral-wound paper or composite materials of sufficient thickness and rigidity for providing side walls of the container, and characterized by forming in situ within the structure a thin-walled vessel of mater constituting a barrier for enclosing and protecting a product to be contained within the vessel, the vessel being formed with a wall thickness ..inadequate for permitting the vessel conventionally to serve alone as a container for such product, wherein the step of forming vessel is effected by utilizing the structure as a mold cavity while a sheet of a selected polymer or , resin is forced into the structure. 26. A method as set forth in Claim 25 and further comprising forming a flange at the upper end of said vessel by the use of lip ring means of the mold.

- OREX

OMPI