GB2610396A

GB2610396A - Improvements in or relating to thermoformed containers

Info

Publication number: GB2610396A
Application number: GB2112483.9A
Authority: GB
Inventors: Bagnall Paul
Original assignee: Innavisions Ltd
Current assignee: Innavisions Ltd
Priority date: 2021-09-01
Filing date: 2021-09-01
Publication date: 2023-03-08
Also published as: GB202112483D0

Abstract

A thermoformed plastic container has a base 12 and an upstanding wall 14 surrounding the base, the upstanding wall terminating at a distal edge thereof to define a mouth 20 of the container. The upstanding wall includes an outwardly projecting rib 28 (figure 2) comprising a first rib wall 30 (figure 2) projecting outwardly from the upstanding wall and a second rib wall 32 (figure 2) returning to said upstanding wall, where the first rib wall is curved and/or is angled in a direction away from the base. The first rib wall may be angled with respect to the upstanding wall 14 within the range 100-180o, or 110-170o, or 130-150o. The rib 28 may be curved in a direction away from the base 12, with the first rib wall 30 being continuously curved. The profile of the rib 28 may change around the container.

Description

Improvements in or Relating to Thermoformed Containers

FIELD

The present teachings relate to a thermoformed plastic container.

BACKGROUND

The present invention relates to a thermoformed plastic container. Particularly, the present invention relates to a thermoformed plastic food container suitable for liquid or semi-solid foodstuffs such as, for example, soups, sauces, yoghurt and other dairy products. The food container of the present invention may also be used to contain solid foodstuffs such as, for example, nuts, dried fruit pieces and the like.

Food containers may be provided with a decorative cover or sleeve made of cardboard or a similar material. For these known containers, the covers may be require an adhesive to be attached to the container, and also may be unable to extend the full height of the container wall.

The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art.

SUMMARY

According to a first aspect there is provided a thermoformed plastic container comprising: a base; and an upstanding wall surrounding the base, the upstanding wall terminating at a distal edge thereof to define a mouth of the container, wherein the upstanding wall comprises an outwardly projecting rib comprising a first rib wall projecting outwardly from the upstanding wall and a second rib wall returning to said upstanding wall, and wherein the first rib wall is curved and/or is angled in a direction away from the base.

Providing a rib wall that projects from the upstanding wall at an angle (i.e. a nonzero angle) relative to the base and/or that is curved away from the base has been found to facilitate the fitting of a cover/sleeve (i.e. a decorative card) around the upstanding wall.

In one arrangement, when the first rib wall is arranged at an angle relative to the base, the angle between the upstanding wall and the first rib wall is in the range 100-180 degrees.

Providing a rib wall that projects from the upstanding wall at an angle in this range has been found to be particularly effective at facilitating the fitting of a cover (i.e. a decorative card) around the upstanding wall and over said rib.

In one arrangement, the angle between the upstanding wall and the first rib wall is in the range 110-170 degrees.

Providing a rib wall that projects from the upstanding wall at an angle in this range has been found to be particularly effective at facilitating the fitting of a cover (i.e. a decorative card) over the rib.

In one arrangement, the angle between the upstanding wall and the first rib wall is in the range 130-150 degrees.

In one arrangement, when the first rib wall is curved in a direction away from the base, said first rib wall defines a continuously curved surface.

Providing a continuously curved first rib wall provides a curved lower surface of the rib (i.e. on the side proximate to the base), facilitate the fitting of a cover/sleeve (i.e. a decorative card) around the upstanding wall.

In one arrangement, the profile of the rib changes around the upstanding wall.

This enables the functionality of the rib to be varied at different positions around the container.

In one arrangement, the rib comprises a plurality of shoulder regions in which the first rib wall portion is substantially parallel to the base.

This facilitates stacking of the containers.

In one arrangement, the plurality of shoulder regions are equally spaced around the upstanding wall.

In one arrangement, the container comprises a plurality of corners, wherein a shoulder region is provided at each of the plurality of corners.

In one arrangement, the upstanding wall terminates at a flange that extends around the periphery of a distal edge of the upstanding wall to define a mouth of the container.

In one arrangement, the flange and shoulder regions are arranged such that the shoulder regions of the container are seated on the flange of a further container, when the container is nested within said further container.

In one arrangement, the upstanding wall comprises a reinforcing arrangement.

This increases the strength of the tray, enabling the thickness of the tray to be reduced.

In one arrangement, the reinforcing arrangement comprises a series of reinforcing ribs extending in a direction between the base and the distal edge of the upstanding wall.

In one arrangement, the reinforcing arrangement comprises a castellated region extending around, e.g. extending entirely around, the upstanding wall.

The castellated surface of the upstanding wall form vertical ribs (i.e. extending in a direction between the base and the distal edge of the upstanding wall) that provide additional strength to the tray, thus enabling the amount of material used in the tray to be reduced. The castellated surface also provide insulation pockets between the tray and a cover/sleeve.

In one arrangement, the first and second rib walls are arranged so as to be substantially symmetrical.

This arrangement has been found to improve the structural strength of the rib, which in turn improves the mechanical securement of a cover to the rib.

In one arrangement, the rib is positioned at a distal end region of the upstanding wall.

In one arrangement, the rib defines a recess on an inner surface of the upstanding wall that is configured for receiving a lateral edge of a container lid to secure said container lid to the container.

In this way, the rib is capable of both providing a mechanical attachment for a cover on the external surface thereof, whilst also providing a mounting location for a container lid on the internal surface thereof.

In one arrangement, the container comprises a lid attached to the container, wherein the lateral edge of the container lid substantially conforms to the surface of the recess.

This has been found to provide improved inter-engagement between the lateral edge of the container lid and the container.

According to a second embodiment, there is provided a container assembly, comprising: a thermoformed plastic container according to the first aspect; and a tray or sleeve comprising a perimeter wall defining an opening for receiving the thermoformed plastic container therein such that the perimeter wall extends around the upstanding wall, wherein the perimeter wall is mechanically fixed the to the rib of the upstanding wall.

In one arrangement, the perimeter wall is dimensioned to substantially match the external dimensions of the upstanding wall.

In one arrangement, the rib comprises a plurality of enlarged regions in which the footprint of the rib is greater than that of the perimeter wall.

In one arrangement, the enlarged regions are provided by shoulder regions are arranged to be seated on the flange of a further container, when the container is nested within said further container.

In one arrangement, the perimeter wall extends from the distal edge of the upstanding wall to the base, when the perimeter wall is mechanically fixed to the rib of the upstanding wall.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 shows an isometric view of a container according to an embodiment; Figure 2 shows an enlarged cross-sectional side view of a part of the container of Figure 1; Figure 3 shows an enlarged cross-sectional side view of a part of the container of Figure 1; Figure 4 shows an isometric view of a container assembly according to an embodiment; Figure 5 shows an enlarged cross-sectional side view of a part of the container assembly of Figure 4; Figure 6 shows an isometric exploded view of a container assembly according to an embodiment; and Figure 7 shows an enlarged cross-sectional side view of a part of the container assembly of Figure 6.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring to Figures 1 to 4, there is shown a container generally designated 10. The container 10 has a base 12 and an upstanding wall 14 surrounding the base 12. The upstanding wall 14 extends to and terminates at a flange 16 extending around the periphery of the container 10 (i.e. around the periphery of the upstanding wall 14). The base 12 and wall 14 co-operate to define an interior space 18 of the container 10. The flange 16 further defines a mouth 20 of the container 10.

The container 10 is manufactured from sheet polyethylene terephthalate (PET) by thermoforming. The container 10 may alternatively be manufactured from sheet polypropylene (PP) by thermoforming. It will be understood that the term "thermoforming" refers to the forming of the container by the thermal softening of a sheet of plastic material, which is then conformed to the shape of a mould. In alternative arrangements, any suitable plastics material may be used. As an alternative, the container 10 may be formed from sheet RPET that can contain up to 100% recycled post-consumer waste. In yet a further embodiment, the container 10 may be formed from laminated PET/RPET having an A/B/A structure with 100% RPET in the central layer and two outer layers of PET. Any thickness combination is possible. For a sheet thickness of 1000micron, the layers may be as follows -with 100 PET/ 800 RPET / 100 PET.

The container 10 is generally rectangular in shape. The upstanding wall 14 tapers towards the base 12, which allows empty containers 10 to be nested within one another for storage and transportation. Put another way, the upstanding wall 14 defines a width that reduces from a maximum width at the distal end of the upstanding wall 14 to a minimum width at the base 12. The shape of the container may be circular, rectangular, hexagonal, octagonal or any other suitable shape. It will be appreciated that the container 10 may have other shapes and volumes to suit the application.

The flange 16 includes a substantially flat or planar annular upper surface 22 that surrounds the mouth 20 of the container 10. The flange 16 includes a peripheral edge 24. The peripheral edge 24 is defined by a lip 24 extending in a direction towards the base 12. The annular surface 22 defines an attachment location for a flexible lid formed from a plastic film or a metal foil. As noted above, the annular surface 22 is flat. The plane of the annular surface 22 is substantially parallel to the plane of the base 12 of the container 10. The film or foil may be attached to the annular surface by adhesive or by the application of heat and pressure. The peripheral edge 24 of the flange 16 may be used to retain a rigid replaceable plastic lid (not shown) that is configured to fit over the flange 16.

Referring to Figure 2, the upstanding wall 14 includes an outwardly projecting rib 28. The rib 28 is positioned on the upstanding wall 14 such that it is proximal to the distal edge thereof. The rib 28 includes a first rib wall 30 projecting outwardly from the upstanding wall 14. The rib includes a second rib wall 32 is substantially planar. The second rib wall 32 terminates at the flange 16. The second rib wall 32 tapers inwardly towards it distal edge (i.e. towards the flange 16). In the illustrated arrangement, the first and second rib walls 30, 32 are substantially planar. T In the illustrated arrangement, the first and second rib walls 30, 32he first and second rib walls 30, 32 are arranged so as to be substantially asymmetrical, although in some alternate arrangements the rib walls 30, 32 may be symmetrical.

The rib 28 defines a recess 34 on an inner surface of the upstanding wall 14.

Although not illustrated, the recess 34 may be configured to receive a lateral edge of a container lid to secure said container lid to the container 10. The lateral edge of the container lid may substantially conform to the surface (i.e. the shape) of the recess 34.

The rib 28 includes a plurality of regions in which the first rib wall 30 is arranged at an angle relative to the base 12 (i.e. the plane of the base 12). Put another way, in these regions, the first rib wall 30 is arranged so as to project away from the upstanding wall 14 in a direction away from the base 12. The angle between the upstanding wall 14 and the first rib wall 30 may be in the range 100°-180°, it may be in the range 110°-170°, or it may be in the range 120°-160°. In some arrangements, the angle between the upstanding wall 14 and the first rib wall 30 may be in the range 130°-150°, for example it may be approximately 130°, approximately 140°, or approximately 150°. In the illustrated arrangement, the regions in which the first rib wall 30 is arranged at an angle relative to the base 12 are provided along the side walls of the container 10. It will be appreciated, however, that these regions may be arranged anywhere on the container.

The profile/shape of the rib 28 changes around the upstanding wall 14. This changing profile enables different parts/regions of the rib 28 to provide different functionality. In alternative arrangements, it will be appreciated that the profile of the rib 28 may be substantially constant around the upstanding wall 14 of the container 10.

Referring to Figure 3, the rib 28 includes four shoulder regions 36. The shoulder regions 36 are provided at each corner of the container 10. The shoulder regions 36 are positioned between regions of the rib in which the first rib wall 30 is arranged at an angle relative to the base 12. It will be appreciated that any suitable number of shoulder regions 36 may be provided. In some arrangements, the shoulder regions 36 may be equally spaced around the upstanding wall 14, e.g. when the container 10 is substantially circular. In further alternative arrangements, it will be appreciated that the shoulder regions 36 may be omitted.

In the shoulder regions 36, the plane of the first rib wall 30 is substantially parallel to the plane of the base 12 of the container 10. In the shoulder regions 36, the first rib wall 30 defines a substantially planar surface. This arrangement of the shoulder regions 36 facilitates stacking of the containers 10 when empty containers 10 are nested within one another for storage and transportation as is illustrated in Figures 2 and 3. The flange 16 and shoulder regions 36 are arranged such that the first rib wall 28 in the shoulder regions 36 of the container 10 are seated on the flange 16 of a further container 10, when the container 10 is nested within said further container 10.

The upstanding wall 14 is provided with a reinforcing arrangement. The reinforcing arrangement increases the strength of the container 10, which enables the thickness of the container 10 to be reduced. In the illustrated arrangement, the reinforcing arrangement is provided in the form of a castellations 38 on the upstanding wall 14. Put another way, the reinforcing arrangement is provided in the form of a series of reinforcing ribs 38 forming a castellated surface. The castellated surface 38 of the upstanding wall 14 forms a series of upright ribs that provide additional strength to the container 10. It will be appreciated that the ribs substantially extend in a direction between the base and the distal edge of the upstanding wall 14. The castellated region 38 extends around, e.g. extends entirely around, the upstanding wall 14.

The castellated surface 38 (i.e. the upright ribs projecting from the upstanding wall 14) work to provide insulation pockets between the container 10 and a cover/sleeve fitted thereto.

Referring now to Figures 4 and 5, during assembly, a tray 40 may be fitted to the container 10 to form a container assembly 42. In the illustrated embodiment, the tray 40 includes a base wall 43 and a perimeter wall 44. In some arrangements, the base wall 43 may be omitted and the tray 40 may be considered to be a sleeve.

The tray or sleeve 40 includes a perimeter wall 44. The perimeter wall 44 defines an opening for receiving the thermoformed plastic container 10 therein. The perimeter wall 44 extends around the upstanding wall 14. Put another way, the container 10 is received in the opening of the tray or sleeve 40 such that the perimeter wall 44 surrounds the upstanding wall 14. The tray or sleeve 40 may be a decorative card. The tray or sleeve 40 is mechanically fixed to the container 10.

The tray or sleeve 40 is mechanically fixed to the rib 28. This arrangement has been found to reduce or remove the requirement for attaching the tray or sleeve 40 to the container 10 using adhesives.

As is shown, the perimeter wall 44 of the tray or sleeve 40 substantially extends the full height of the upstanding wall 14. Put another way, the tray or sleeve 40 is arranged to substantially extend between the base 12 and the flange 16. The castellated surface 38 (i.e. the upright ribs projecting from the upstanding wall 14) work to provide insulation pockets between the container 10 and a cover/sleeve fitted thereto. The rib 28 works to provide a spacing between the tray or sleeve 40.

The perimeter wall 44 of the tray or sleeve 40 contacts the wall (i.e. is mechanically fixed to) the rib 28 and proximate to a perimeter of the base 12 (i.e. proximate a proximal edge of the upstanding wall 14).

The perimeter wall 44 is dimensioned to substantially match the external dimensions of the upstanding wall 14. Put another way, the perimeter wall 44 and the upstanding wall 14 are configured and arranged to provide a close fit there between. The rib 28 is provided with a plurality of enlarged regions in which the footprint of the rib 28 is greater than the footprint of the perimeter wall 44. In the arrangement shown, the enlarged regions are provided by the shoulder regions 36 (i.e. in the corners of the container 10), but it will be appreciated that they may be positioned differently in alternative arrangements. These enlarged regions grip the corresponding regions of the perimeter wall 44 and pull the side wall portions of the perimeter wall 44 on the rib 28, so as to increase the mechanical engagement between the tray or sleeve 40 and the container 10.

Referring now to Figures 6 and 7, a container is illustrated and is indicated generally at 100. Corresponding components of these figures with respect to Figures 1 to 5 are labelled with the prefix '1', and only differences are discussed in more detail.

The container 110 is generally frusto-conical in shape which allows empty containers 110 to be nested within one another for storage and transportation. It will be appreciated that the container 110 may have other shapes and volumes. The upstanding wall 114 tapers towards the base 112, which allows empty containers 110 to be nested within one another for storage and transportation. Put another way, the upstanding wall 114 defines a width that reduces from a maximum width at the distal end of the upstanding wall 114 to a minimum width at the base 112.

The upstanding wall 114 includes an outwardly projecting rib 128. The rib 128 includes a first rib wall 130 projecting outwardly from the upstanding wall 114. The rib 128 includes a second rib wall 132 returning to said upstanding wall 114.

The first rib wall 130 is curved in a direction away from the base 112. The first rib wall 130 defines a continuously curved surface. In the arrangement shown, the first rib wall 130 defines a radius of curvature that is substantially constant. The second rib wall 132 is substantially planar. The second rib wall 132 terminates at the flange 116. The second rib wall 132 tapers inwardly towards its distal edge (i.e. towards the flange 116).

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims.

Claims

Claims 1. A thermoformed plastic container comprising: a base; and an upstanding wall surrounding the base, the upstanding wall terminating at a distal edge thereof to define a mouth of the container, wherein the upstanding wall comprises an outwardly projecting rib comprising a first rib wall projecting outwardly from the upstanding wall and a second rib wall returning to said upstanding wall, and wherein the first rib wall is curved and/or is angled in a direction away from the base.
2. The container according to claim 1, wherein, when the first rib wall is arranged at an angle relative to the base, the angle between the upstanding wall and the first rib wall is in the range 100-180 degrees.
3. The container according to claim 2, wherein the angle between the upstanding wall and the first rib wall is in the range 110-170 degrees.
4. The container according to claim 3, wherein the angle between the upstanding wall and the first rib wall is in the range 130-150 degrees.
5. The container according to any preceding claim, wherein, when the first rib wall is curved in a direction away from the base, said first rib wall defines a continuously curved surface.
6. The container according to any preceding claim, wherein the profile of the rib changes around the upstanding wall.
7. The container according to claim 6, wherein the rib comprises a plurality of shoulder regions in which the first rib wall portion is substantially parallel to the base.
8. The container according to claim 7, wherein the plurality of shoulder regions are equally spaced around the upstanding wall.
9. The container according to claim 7, comprising a plurality of corners, wherein a shoulder region is provided at each of the plurality of corners.
10. The container according to any preceding claim, wherein the upstanding wall terminates at a flange that extends around the periphery of a distal edge of the upstanding wall to define a mouth of the container.
11. The container according to claim 10 when dependent upon claim 7, wherein the flange and shoulder regions are arranged such that the shoulder regions of the container are seated on the flange of a further container, when the container is nested within said further container.
12. The container according to any preceding claim, wherein the upstanding wall comprises a reinforcing arrangement.
13. The container according to claim12, wherein the reinforcing arrangement comprises a series of reinforcing ribs extending in a direction between the base and the distal edge of the upstanding wall.
14. The container according to claim 12 or claim 13, wherein the reinforcing arrangement comprises a castellated region extending around, e.g. extending entirely around, the upstanding wall.
15. The container according to any preceding claim, wherein the first and second rib walls are arranged so as to be substantially symmetrical.
16. The container according to any preceding claim, wherein the rib is positioned at a distal end region of the upstanding wall.
17. The container according to any preceding claim, wherein the rib defines a recess on an inner surface of the upstanding wall that is configured for receiving a lateral edge of a container lid to secure said container lid to the container.
18.The container according to claim 17, comprising a lid attached to the container, wherein the lateral edge of the container lid substantially conforms to the surface of the recess.
19. The container according to any preceding claim, wherein the container is formed from polypropylene or polyethylene terephthalate.
20.A container assembly, comprising: a thermoformed plastic container according to any preceding claim; and a tray or sleeve comprising a perimeter wall defining an opening for receiving the thermoformed plastic container therein such that the perimeter wall extends around the upstanding wall, wherein the perimeter wall is mechanically fixed the to the rib of the upstanding wall.
21. The container assembly according to claim 20, wherein the perimeter wall is dimensioned to substantially match the external dimensions of the upstanding wall.
22. The container assembly according to claim 20 or claim 21, wherein the rib comprises a plurality of enlarged regions in which the footprint of the rib is greater than that of the perimeter wall.
23. The container assembly according to claim 22, wherein the enlarged regions are provided by shoulder regions are arranged to be seated on the flange of a further container, when the container is nested within said further container.
24. The container according to any one of claims 20 to 24, wherein the perimeter wall extends from the distal edge of the upstanding wall to the base, when the perimeter wall is mechanically fixed to the rib of the upstanding wall.