US20170334612A1

US20170334612A1 - Container

Info

Publication number: US20170334612A1
Application number: US15/522,203
Authority: US
Inventors: Jason Middleton; Spencer Beaufore; Jeremy McBroom
Original assignee: Abbott Laboratories
Current assignee: Abbott Laboratories
Priority date: 2014-10-30
Filing date: 2015-10-20
Publication date: 2017-11-23
Also published as: WO2016069329A1; CN207029948U; CN205738729U

Abstract

A container for holding granular or powdered material. The container includes a base and a lid. The base defines an interior space and an opening to the interior space. The lid is removably attached to the base and adapted to cover the opening. Latches are attached to the outside surface of the lid on opposing sides of the lid. Inwardly extending lugs on the inside surface of the latch are correspondingly positioned to contact deflectors on the outside surface of the base during attachment of the lid to the base.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and any benefit of U.S. Provisional Application No. 62/072,572, filed Oct. 30, 2014, the content of which is incorporated herein by reference in its entirety.

BACKGROUND

Many consumer products are packaged in granular or powdered form, such as for example, infant formula, flour, coffee, and sugar. Stock keeping units of granular or powdered form which are sold in volumes larger than one-time use amounts require specific packaging. The packaging must be suitable for storage until first-time use by a consumer and must subsequently provide adequate storage for the consumer between uses. Adequately storing the product throughout the consumption period of the volume of powder requires packaging which prohibits waste and contamination, is strong and durable, and is convenient to the user.
Large volume consumer powder products have been conventionally offered in a paper cylindrical package with a plastic peel-off lid. Examples of powder products offered for sale in a paper cylindrical package include coffee, ice tea, and infant formula. Powder manufacturers have recently looked to new and innovative containers for many reasons, including durability, contamination, manufacturing waste, and consumer waste.
One example of consumer waste is the loss of powder during the opening of a container. A large volume plastic container having a removable lid may require two-hands to open. If the lid or the base is deformed in the opening process, or the lid requires a relatively significant amount of force to separate it from the base, the powder has a propensity to kick-up and an amount of powder will be lost. Further, the cost of certain high-volume powders makes any powder loss significant.

SUMMARY

The present application describes a container for use in packaging granular or powdered material, such as for example, a container suitable for use in holding powder infant formula.
In an exemplary embodiment, a container has a base and a lid. The base defines an interior space and an opening to the interior space. The lid is removably attached to the base and adapted to cover the opening. Latches are attached to the outside surface of the lid on opposing sides of the lid. Inwardly extending lugs on the inside surface of a latch are correspondingly positioned with deflectors on the outside surface of the base.
Further features and advantages of the invention will become apparent from the following detailed description made with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and advantages of the general inventive concepts will become apparent from the following detailed description made with reference to the accompanying drawings.

FIG. 1 is a top, perspective view of a container;

FIG. 2 is a bottom, perspective view of the container of FIG. 1;

FIG. 3 is an enlarged view of the designated circular area of FIG. 2;

FIG. 4 is a sectional view of the container of FIG. 1, shown along the line 4-4 of FIG. 1;

FIG. 5 is a sectional view of the container of FIG. 1, shown along the line 5-5 of FIG. 1;

FIG. 6 is an enlarged view of the designated circular area of FIG. 4;

FIG. 7A is an enlarged view of the designated circular area of FIG. 5, showing a lid in a closed position;

FIG. 7B is a view of the circular area of FIG. 7A, showing the lid in an initial partially opened position;

FIG. 7C is a view of the circular area of FIG. 7A, showing the lid in an advanced partially opened position;

FIG. 8 is a front view of the container of FIG. 1, the rear view being essentially a mirror image thereof;

FIG. 9 is a left side view of the container of FIG. 1, the right side view being essentially a mirror image thereof;

FIG. 10 is a top view of the container of FIG. 1;

FIG. 11 is a bottom view of the container of FIG. 1;

FIG. 12 is a perspective view of the container of FIG. 1, showing the lid in an open and detached position;

FIG. 13 is a perspective, assembly view of the container of FIG. 1, showing only a base and a seal;

FIG. 14 is a top perspective view of the lid of the container of FIG. 1;

FIG. 15 is a bottom perspective view of the lid of FIG. 14;

FIG. 16 is an enlarged view of the designated area of FIG. 15;

FIG. 17 is a bottom view of the lid of FIG. 14;

FIG. 18 is a sectional view of the lid of FIG. 14, shown along the line 18-18 of FIG. 17;

FIG. 19 is perspective, sectional view of the lid of FIG. 14, shown along the line 19-19 of FIG. 17;

FIG. 20 is a top, perspective view of the base of the container of FIG. 1;

FIG. 21 is a front view of the base of FIG. 20, the rear view being essentially a mirror image thereof;

FIG. 22 is an enlarged view of the designated circular area of FIG. 21;

FIG. 23 is a left side view of the base of FIG. 20, the right side view being essentially a mirror image thereof;

FIG. 24 is an enlarged view of the designated circular area of FIG. 23;

FIG. 25 is a bottom, perspective view of the base of FIG. 20;

FIG. 26 is an enlarged view of the designated circular area of FIG. 25;

FIG. 27 is a perspective, sectional view of the base of FIG. 20, shown along the line 27-27 of FIG. 20; and

FIG. 28 is an enlarged, sectional view of a portion of the base of FIG. 20, shown along the line 27-27 of FIG. 20 and with a second container in a stacked position below the first container.

DETAILED DESCRIPTION

This Detailed Description merely describes exemplary embodiments in accordance with the general inventive concepts and is not intends to limit the scope of the invention or the claims in any way. Indeed, the invention as described by the claims is broader than and unlimited by the exemplary embodiments set forth herein, and the terms used in the claims have their full ordinary meaning.
The general inventive concepts will now be described with occasional reference to the exemplary embodiments of the invention. These general inventive concepts may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the general inventive concepts to those skilled in the art.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art encompassing the general inventive concepts. The terminology set forth in this detailed description is for describing particular embodiments only and is not intended to be limiting of the general inventive concepts. As used in this detailed description and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, percentages, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the suitable properties sought to be obtained in the embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the general inventive concepts are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.
The present application describes a container for use in packaging, such as for example, a container suitable for use in holding powder, such as adult nutritional powder or infant formula. The container provides an advantageous storage method for a granular or powdered product. The container includes a base or receptacle, which contains the powder, and a lid. In shipment, a seal may separate the powder from the lid. At the site of use, the lid may be manually removed and separated from the base by a user. After an initial use, the lid may be reattached to the base for storage until the next use.
The lid offers certain advantageous features. The geometry of the lid dome includes a high dome and side recesses along two opposing sides. The geometry prohibits deformation of the lid and allows a smooth and passive removal of the lid to prohibit the natural propensity of the powder to kick-up during manual removal and detachment of the lid. The high dome of the lid provides a storage area for a scoop which is above the level of the seal.
One embodiment of the invention features a container having a base and a lid. The base defines an interior space and an opening to the interior space. The lid is removably attached to the base and adapted to cover the opening. At least two latches are attached to an outside surface of the lid, one of the at least two latches on one side of the lid and another of the at least two latches on an opposing side of the lid. Each latch has at least one inwardly extending lug on an inside surface of the latch. The container has at least two deflectors, one of the at least two deflectors on one side of the base and another of the at least two deflectors on an opposing side of the base. Each deflector protrudes from an outside surface of the base. Each of the inwardly extending lugs is correspondingly positioned to contact one of the at least two deflectors during attachment of the lid to the base.
Another embodiment of the invention features a container having a base, a lid, at least two latches, and at least two deflectors. The base defines an interior space and an opening to the interior space. The lid is removably attached to the base and adapted to cover the opening. The at least two latches are attached to an outside surface of the lid. One of the at least two latches is on one side of the lid and another of the at least two latches is on an opposing side of the lid. Each latch has at least one inwardly extending lug on an inside surface of the latch. One of the at least two deflectors is on one side of the base and another of the at least two deflectors is on an opposing side of the base. Each deflector protrudes from an outside surface of the base. The base has a collar, and each of the inwardly extending lugs is positioned to nest underneath the collar with the lid in a closed position.
Another embodiment of the invention features a container having walls, a lid, a removable seal, at least two latches, and at least two deflectors. The walls define an interior space and an upper portion. The upper portion defines a sealing flange having an internal edge which defines an opening to the interior space. The lid is removably attached to the upper portion and adapted to cover the opening. The removable seal extends across the opening and attaches to the sealing flange. Further, the seal is positioned between the lid and the sealing flange. The at least two latches are attached to an outside surface of the lid. One of the at least two latches is on one side of the lid and another of the at least two latches is on an opposing side of the lid. Each latch has at least one inwardly extending lug on an inside surface of the latch. The at least two deflectors protrudes from an outside surface of a wall. One of the at least two deflectors is on one wall of the base and another of the at least two deflectors is on an opposing, non-contiguous wall of the base.
Referring now to the drawings, a container 10 for holding a granular or powdered product is shown in FIGS. 1-13. The container is suitable for packaging of product at a manufacturing facility to be sold in volumes larger than one-time use amounts. The exemplary container discussed herein is suitable for use in packaging infant powder formula which is sold in multiple-use amounts. However, it should be understood that the invention can be practiced with any type of granular or powdered product, such as for example, flour, coffee, and sugar, and any packaged volume of granular or powdered product.
The container may be constructed by various methods. The exemplary container is stackable and may be manufactured by an injection molding process. The container includes two primary parts, a base and a lid, and each is injection molded in separate molds. The parts are formed by a direct food contact approved polymer, such as for example, polyethylene or polypropylene. In one manufacturing technique, the bases and lids are shipped in separate stacks from the molder to the powder manufacturer and final filling facility. It will be understood by those skilled in the art that the invention may be practiced by other manufacturing methods and by using other production materials.
Now referring to FIG. 1, a top perspective view of a container is shown. The container 10 includes a base or receptacle 12 and a lid 16. The receptacle 12 and lid 16 are cooperatively arranged such that the lid may be manually attached to and detached from the base by a user. A user may manipulate the lid between a closed position and an open position to access an interior space within the receptacle. The lid may include a gripping area having recesses, a glossy surface, and a favorable coefficient of friction. In production assembly, the interior space of the receptacle is filled with a powder. After a seal is applied to the top of the receptacle to close an opening to the receptacle, the lid is secured by advancing inwardly extending lugs of the inside surface lid beyond reflectors on the outside surface of the receptacle. As discussed herein, the inside surface of the lid may include structure for removably securing a scoop. A tamper-evident shrink band may be applied as an additional safety step.
The base or receptacle 12 is shaped to define an interior space 26 for storing powder. The base 12 has a bottom wall and four side walls to generally form a cuboid with an open top. The opening 24 provides access to the interior space 26 suitable for storing a powder product. During a packaging operation, the interior space 26 is filled with powder and then sealed with a removable sealing layer. The exemplary base 12 has at least two opposing and generally planar sides and a rectangular bottom wall, i.e., is generally in the shape of a rectangular hexahedron. FIGS. 20-27 are views of the base 12 prior to assembly to other components of the container.
The exemplary base or receptacle 12 is formed in part by four vertical walls and a bottom wall. Referring to FIGS. 1-3, 8, and 9, the base 12 generally includes two first walls, or elongated front and rear walls, and two second walls, or shorter side walls. A perspective view of the bottom wall 28 is illustrated in FIG. 2. Generally, the front half of the base is essentially the same as the back half of the base, and the right half of the base is essentially the same as the left half of the base. As discussed herein, absent features to secure a scoop, the front half of the lid is essentially the same as the back half of the lid, and the right half of the lid is essentially the same as the left half of the lid. As such, a user may pick up the lid in any orientation, latches down, and attach to the base in any orientation, opening up. In other words, the lid may be detached from the base, spun 180 degrees, and reattached. This feature provides the user with flexibility during use.
The base or receptacle 12 defines an interior space and an opening to the interior space. As shown best in FIG. 7C, a sealing flange 410 surrounds the opening. The interior space and the opening may be further defined by walls of the base. In the exemplary base shown in FIGS. 1-3, 8, and 9, the two first walls are a front wall 20 a and a rear wall 20 b, and the two second walls are a right side wall 22 a and a left side wall 22 b. The four vertical walls 20 a, 20 b, 22 a, 22 b generally define an opening 24 to an interior space 26 which is generally defined by the five walls 20 a, 20 b, 22 a, 22 b, 28. In regard to a horizontal measurement along the exterior surface of the container, the front wall 20 a and rear wall 20 b are generally the same length, and the right wall 22 a and the left wall 22 b generally the same length. As shown in the Figures, each of the front wall 20 a and the rear wall 20 b is of a greater length than each of the right side wall 22 a and the left side wall 22 b. As such, the walls of the exemplary base 12 generally form the shape of a rectangular hexahedron. It should be understood that the base illustrated in the Figures is for example only and that walls of the container may be of an alternative number, size, shape, and structure in the practice of this invention.
As discussed herein, the lid 16 is removably attached to the base 12 and is adapted to cover the opening 24. For example, the container shown in FIGS. 1 and 2 includes a lid 16 which is attached to the base 12 and covers an opening 24. The structure of the lid 16 also adds to the overall stability and strength of the container 10. To emphasize certain structural features, a lid 16 is shown in various views in FIGS. 14-19 without any other components of the container 10. The lid generally includes a top wall and side walls. In the exemplary lid 10 shown in FIGS. 14-19, the two first walls are a front wall 40 a and a rear wall 40 b, and the two second walls are a right side wall 42 a and a left side wall 42 b. The four vertical walls 40 a, 40 b, 42 a, 42 b generally define an interior space 46 which is generally defined by the five walls 40 a, 40 b, 42 a, 42 b, 48. In regard to a horizontal measurement along the exterior surface of the container, the front wall 40 a and the rear wall 40 b are generally the same length, and the right wall 42 a and the left wall 42 b generally the same length. As shown in the Figures, each of the front wall 40 a and the rear wall 40 b is of a greater length than each of the right side wall 42 a and the left side wall 42 b. The side walls of the lid also have recesses. The front wall 40 a has a recess 41 a and the rear wall 40 b has a recess 41 b. The recesses 41 a, 41 b cover a majority of each sidewall 40 a, 40 b, respectively. As discussed herein, the shape of the lid is advantageous to reduce powder kick-up during manual removal of the lid. It should be understood that the lid illustrated in the Figures is for example only and that walls of the container may be of an alternative number, size, shape, and structure in the practice of this invention.
As discussed herein, the container includes a base and a lid which are cooperatively arranged such that the lid may be manually attached to and detached from the base by a user. The lid includes latches and the base includes deflectors which are correspondingly positioned to each other. In one embodiment, the latches are correspondingly positioned to contact one or more of the deflectors during attachment of the lid to the base. At least two latches are attached to an outside surface of the lid. At least one latch is located at one side of the lid and at least one latch is located at an opposing side of the lid. In the exemplary lid 16, the lid is generally rectangular shaped, and the latches are located on non-contiguous sides. As such, a user may open the lid using either latch at either end of the container.
Referring now to FIGS. 14-19, an exemplary lid 16 is illustrated. The lid 15 is generally rectangular shaped and has two opposing walls 42 a, 42 b. Each wall 42 a, 42 b includes a single latch 52 a, 52 b, respectively, and each latch is positioned to extend downward beyond the bottom edge 408 of a lid collar 406 which surrounds the bottom of the lid 16, as best seen in FIGS. 3 and 14. As discussed herein, each downwardly extending latch 52 a, 52 b offers the user a contact point for use in manually removing the lid 16. It should be understood that the illustrated latches are for example only and that latches may be of an alternative number, size, shape, and structure in the practice of this invention.
Each latch 52 a, 52 b includes structure to attach the lid to the base. Referring now to FIG. 18, a sectional view of the lid of FIG. 14 is shown along the line 18-18 of FIG. 17. In other words, the sectional view is along the length of the generally rectangular shaped lid 16. As is shown in FIGS. 15-18, each latch 52 a, 52 b includes at least one inwardly extending lug on an inside surface of the latch. The first latch 52 a has two lugs 210 a, 210 b which extend inward from the inside surface 214 of the first latch 52 a. The lugs are best shown in FIGS. 7A-7C, 15, 16, 18 and 19. For example, FIG. 14 is a top perspective view of a lid 16, FIG. 15 is a bottom perspective view of the lid of FIG. 14, and FIG. 16 is an enlarged view of the designated area of FIG. 15. In FIG. 16, the two lugs 210 a, 210 b are shown in a position protruding inward from the inside surface 214 of the first latch 52 a. In the illustrated embodiment, the exemplary lid 16 has two ends which are identical. As shown, the second latch 52 b has two lugs 212 a, 212 b in a position protruding inward from the inside surface 216 of the second latch 52 b in the same manner as lugs 210 a, 210 b.
As discussed herein, a consumer may open the lid by lifting a latch at either side of the container. For clarity, further discussion will focus on one end of the container, but as discussed herein, the opposing end of this exemplary container is identical. Thus, a user may remove a lid from a base, and after use of a predetermined amount of powder, connect the lid to the base in the same orientation as the lid was removed, or in a 180 degree orientation relative to the orientation in which the lid was removed.
The present disclosure is also directed to deflectors on the base which contact the lugs during attachment and during removal of the lid. An exemplary container has at least two deflectors. At least one of the deflectors is on one side of the base and at least one deflector is on an opposing side of the base. FIGS. 20-22 illustrate an exemplary base 12 having two deflectors at each of two opposing sides of a base 12. Each deflector is located on the outside of the base and, specifically, on the collar of a base. The exemplary deflectors are formed by a set of three ribs protruding from an outside surface of the base, but the invention may be practiced by deflectors having a different structure. As discussed herein, the inwardly extending lugs of the lid are correspondingly positioned to contact one of the deflectors during attachment of the lid to the base. The lid snaps onto the container in order to provide protection and containment of the internal contents of the container. The snap-fit of the lugs onto the collar of the base container delivers audible and tactile feedback to the user that signifies a secure closure of the lid to the container.
A user will remove the snap-on lid by disengaging the lugs of the lid latch from underneath the base collar to allow the components to separate. As the lid is removed, the latch lugs glide along the deflection ribs. After removing the necessary contents from the container, the user replaces the lid onto the container. As the lugs of the lid latch pass over the top flange of the base, the lugs align with the deflection ribs, glide down the deflection ribs, glide downward past the base collar, and snap under the collar to secure the lid to the container. Without the deflection ribs, the lugs of the lid latch have the tendency to ‘catch’ the underside of the container top flange causing an unfavorable removal. The inventive snap-fit of the lugs onto and under the base collar advantageously delivers audible and tactile feedback to the user that signifies a secure closure of the lid to the container. If the deflection ribs are not incorporated into the base collar, the latch lugs will catch the underside of the container top sealing flange during removal and negatively impact the opening, such as for example, the powder may kick-up and cause product loss.
As discussed herein, the base of the container may be constructed by various methods. An exemplary base is manufactured by an injection molding process using a dedicated mold. The base is formed by a direct food contact approved polymer, such as for example, polyethylene or polypropylene. A single mold may include the base, the collar, the top flange, and the deflecting ribs. In one manufacturing technique, the base is shipped in separate stacks from the molder to the powder manufacturer and final filling facility. It will be understood by those skilled in the art that the invention may be practiced by other manufacturing methods and by using other production materials.
Referring now to the exemplary base 12, the deflector of the base is best shown in FIGS. 20-27. A top perspective view and a front view of the exemplary base 12 are shown in FIG. 20 and FIG. 21, respectively. The base 12 includes four deflectors, two at each opposing side on the base 12. On one wall 22 a of the base, two deflectors 300, 302 extend outward from the collar of the base and from an opposing wall 22 b (see FIG. 25), two deflectors 304, 306 extend outward from the collar. Each deflector includes a plurality of spaced apart deflection ribs. As best seen in the enlarged views in FIGS. 24 and 26, the set of deflection ribs includes three ribs which are vertically positioned. It should be understood that the deflectors 300, 302, 304, 306 are for example only, and that deflectors of other shape, size, and quantity may be used in the practice of this invention.
Still referring to the deflectors, FIG. 24 is an enlarged view of the designated circular area of FIG. 23. The deflector 300 is illustrated having three ribs 300 a, 300 b, 300 c. The ribs 300 a, 300 b, 300 c are equally spaced and vertically orientated. All four deflectors 300, 302, 304, 306 have the same geometry. For example, each deflection rib has an outward facing surface which is sloped downward. FIGS. 21 and 22 illustrate a front view and an enlarged view of deflector 304. As shown, the outward facing surface 314 of each rib of the deflector 304 slopes downward. Thus, each rib defines an lug engagement angle relative to the base. The ribs of the exemplary base form an angle α₁. In one embodiment, the lug engagement angle may be more than 45 degrees and less 90 degrees, such as for example 60 degrees, relative to the base, and, specifically, relative to the horizontal surface of the base bottom wall. A perspective view of one of the deflectors is shown in FIG. 26. An enlarged view of deflector 304 is shown having three ribs 304 a, 304 b, 304 c. The ribs are illustrated in a equally spaced position.
As discussed, the Figures illustrate the deflection ribs from different perspectives. In the exemplary rectangular-shaped base, each base has a total of four deflectors, two deflectors on each side of two non-contiguous sides. The deflection ribs are visibly extending down to the outside edge of the base collar. For example, the deflector 304 shown in FIG. 22 includes ribs having a downwardly extending surface 314 which extends downward to the top of the base collar 402. By extending the ribs downward to the outside edge of the collar, the latch lugs may slide between the deflection ribs and the base collar 402 in either direction in an essentially uninterrupted path of motion.
The interaction between the lugs of the latches and the deflectors of the base will now be discussed. Enlarged and sectional views on the interaction of the base and the lid are shown in FIGS. 6 and 7A-7C. The rectangular-shaped exemplary container 10 has four sides, two-sides with a latch on the lid, and two elongated sides without a latch. FIGS. 1, 4, and 5 illustrate this feature. Referring now to FIG. 6, an enlarged view of the designated circular area of FIG. 4 is shown. An elongated side wall 20 a of the container 10 is shown. The lid 16 includes a collar 406. The collar 406 extends downward to an edge 408 positioned just above the collar 402 of the base 12. The opposing elongated side is essentially the same in construction.
FIGS. 7A-7C illustrate one of the two sides of the base having a latch on the lid, with the latch shown in a variety of positions relative to the base. Referring to FIG. 7A, an enlarged view of the designated circular area of FIG. 5 is shown. The lid 12 is shown in a closed position. As shown, the lug 210 a extends inward from the inside wall 214 of the latch 52 a and is positioned to nest underneath the collar 402 of the base 12 with the lid in a closed position. A top horizontal surface 412 of the lug rests beneath the base collar when the lid is in the closed position. In the exemplary lug 210 a, the lug extends inward to touch the side wall 22 a of the base 12.
The latch and the deflectors are correspondingly arranged for passive opening of the lid by a user. To do so, a user must secure the base, typically with one hand and then engage the bottom tip of one of the latches with the other hand. Several illustrations of the movement of the lid is shown in FIG. 7B. The lid 16 is shown in an initial, partially opened position in FIG. 7B. By rotating the bottom edge 204 of the latch 52 a in a direction R₁away from the base 12, the lug 210 will move out from under the base collar, and up the vertical side surface 403 of the base collar 402 in a direction toward the flange 410 of the base. When the lid is being closed, the lug 210 a will assume the same or similar position against the vertical side surface 403 of the base collar 402 when moving in a downward position.
Discussing again opening the lid, the user must continue to advance the lid with contact on the bottom edge of the latch. FIG. 7C shows the lid 12 in an advanced partially opened position after the latch has advanced in a direction A₁toward the flange 410 of the base. In this position, the lug is now in contact with the angled surface 314 of each of the three ribs of the deflector. When the lid is being closed, the lug 210 a will assume the same or similar position against the angled surface 314 of the ribs when moving in a downward position. However, as the user continues to lift the latch 52 a in the direction A₁, the latch will clear the flange 410 of the base, and the lid can be completely separated from the base without any powder kick-up.
When the lid is reattached, the movement of the latches and the lugs is essentially repeated in the opposite direction by at least one side of the lid. In other words, one side of the lid may be engaged to the collar as the other side is attached. As discussed herein, movement of the lugs in a downward direction beyond the collar of the base at one side of the base produces an audible engagement. In view of the same pattern for attachment and removal, each of the inwardly extending lugs at one side of the base is movable in two directions, i.e., both upward and downward, along the outside surface of the collar with the lugs at the opposing side of the base engaged to the collar. Further, each of the inwardly extending lugs at one side of the base is movable in two directions, i.e., both upward and downward, along the outside surface of one of the at least two deflectors with the lugs at the opposing side of the base engaged to the collar.
The container may include a seal which is removable by the consumer. The seal is used to protect the contents of the container after packaging, during shipment, and during storage prior to sale. The sealing layer may help to preserve freshness or indicate tampering. Any suitable seal material may be selected, such as for example, a material suitable to protect the contents from moisture, oxygen and light. The seal may be constructed from a substantially moisture-impervious, oxygen-impervious material, such as for example, aluminum foil, or a foil made of some other metallic material, or a combination of a layer of materials that can include a metallic, a polymeric, and other material layers.
Referring now to FIG. 12, a perspective view of the container 10 is shown with the lid in an open and detached position. In this stage of packaging, the base contains a powdered product and a sealing layer has been attached to the top surface of the base. The removable seal extends across the opening of the base and is attached to the sealing flange. FIG. 13 shows only the seal 14 and the base 12 with the seal in a removed position.
The seal may be adhered to the base by a pressing operation. In the exemplary seal shown, an impression pattern has been left upon a top surface of the seal. In the practice of this invention, alternative impression patterns may be left upon a top surface of the seal or no impression pattern may be left upon a top surface of the seal.
After the seal is removed, the exemplary container 10 does not include a gasket or any other sealing mechanism beyond the base and the lid. However, structure of the lid acts as a dam to prohibit flow of the powder outside of the container when the lid is closed. The lid includes a bead which follows a circumferential path near the outer edge of the underside of the lid. The bead is best shown in FIGS. 6, 7C, and 16. The bead may be contiguous with the sealing flange with the lid in the closed position. For example, FIG. 6 shows a sectional view of the lid along the elongated side of the container 10 and with the lid in the closed position. The lid includes a thin bead 500 which protrudes down from an inside surface of the lid near the collar 406 of the lid. The bead thickens in the areas of the path which are near the latches. For example, FIG. 16 is a bottom perspective view of a single latch 52 a. The thin bead 500 can be seen on either side of a thicker bead portion 502, that is to say, in a closed position the bead is wider horizontally from the inside of the container to the outside. As shown in the sectional view in FIG. 7C, the thicker bead 502 offers a more secure and wider dam against the sealing flange 410 in areas near the latch which are points of opening and closing and more susceptible to powder leaking.
The present disclosure also includes a scoop retention feature. In a conventional powder container, a measuring scoop may be placed within the base of a container along with the powder or granular contents. In this position, a user often is forced to dig with their fingers or a utensil to locate and retrieve the scoop. This technique may soil the user's hand with the powder and moreover, puts the powder at risk of contamination, either from the user's hands or the utensil used to locate and retrieve the measuring scoop. A leading consumer complaint in high-volume powder packages is the scoop being disposed within the powder when the package is initially opened by the consumer.
The disclosure includes structure on the underside of the lid to retain and store a scoop. The scoop is disposed in a position above the level of the powder and above the level of the membrane seal of the package. The overcap lid is domed to create enough volume in order to hold multiple sizes of measuring scoops. The scoop retention structure may be a retention clip to hold a scoop of more than one size and to hold scoops having a measuring bowl of more than one size. The scoop retention clip may be disposed in the dome of an overcap lid.
As discussed herein, the domed lid with the scoop retention structure may be manufactured in, but not limited to, a direct food contact approved polymer such as polyethylene or polypropylene. The manufacturing process for the domed lid with scoop retention structure will likely use, but is not limited to, an injection molding process. The packaging components will be manufactured at the packaging supplier and sent to the filling facility. A flexible membrane is sealed to the top flange of the base. The measuring scoop may be placed on top of the sealed flexible membrane or may be engaged within the scoop retention feature of the overcap lid. The snap-on overcap lid is applied to the container.
The scoop retention structure is located in the dome of the overcap lid and above the contents of the container, thereby giving the user easy access to the scoop. The structure allows the user to grip and remove the measuring scoop from the lid without soiling the user's hands or contaminating the powder. The present invention includes the manufacturing technique of sealing the base with a membrane seal before the scoop is secured into the retention structure in the lid dome, and at a height above the level of the membrane seal and above the level of the powder.
The scoop retention structure may hold a scoop of more than one size and may hold scoops having a measuring bowl of more than one size. The structure is arranged such that the bowl of the scoop is secured, rather than the handle of the scoop. In one embodiment, a tongue is inserted into the measuring bowl to secure the scoop. The tongue is biased inward toward the roof of the dome to secure the measuring bowl.
Referring now to FIGS. 15, 17 and 19, the scoop retention structure is a clip 98 and is positioned on the dome ceiling. With the lid 16 attached to the base 12, the scoop clip 98 is at a location in the lid which is above the flexible sealing membrane. A perspective, sectional view of the lid is shown in FIG. 19. The lid 16 offers storage for a scoop 110 when packaged and not in use by the consumer. A scoop is shown in FIGS. 4, 5, 12, and 28, for example, but for clarity the scoop is not included in other figures. The clip 98 is positioned to secure the measuring bowl of the scoop only, allowing for a scoop having a bowl 112 of varying shape, size and volume.
The scoop clip 98 includes a foundation 100 and a tongue 102. The tongue 102 extends to a tongue distal end 104, which is inserted into the open side of a measuring bowl of a scoop, as shown in FIGS. 4, 5 and 12, and in a direction generally parallel to the longitudinal axis of the measuring bowl. In other words, the measuring bowl does not “snap in” to a secure position, but rather the distal end of the tongue is slid into the measuring bowl.
Another view of the scoop clip 98 is shown in FIG. 28, which is an enlarged, sectional view of a portion of the base 12 of FIG. 20, shown along the line 27-27 of FIG. 20. An upper container 10 is illustrated in a stacked position above and engaged with a lower container 10′. In this view, the positioning of the scoop 110 is seen between the membrane seal 14′ and the ceiling of the lid 16′ of the lower container 10′. The scoop 110 has a measuring bowl 112 and a handle 114. The tongue 102 of the clip 98 is shown extending into an opening 116 in the measuring bowl 112. As shown, the diameter D₁of the measuring bowl 112 is less than the height H₁from the membrane seal 14 and the ceiling of the lid 16′ of the lower container 10′. The dome of the lid 16′ is structured to accommodate scoops having a measuring bowl of a variety of diameters, including scoops having a measuring bowl with a diameter D₁equal to and less than the height H₁from the membrane seal 14′ and the ceiling of the lid 16′ of the lower container 10′. Further, the diameter D₁of the measuring bowl 110 must be equal to or greater than the width W₁of the tongue 102. The illustrated clip 98 is for example only, and the invention may be practiced with clips of other location, size, shape and quantity.
The present disclosure is also directed to a stackable package. The stackable package is suitable for storing consumer products, such as powder. The inventive disclosure includes an overdome lid which may create sufficient volume in order to hold a measuring scoop or spoon. The overcap lid snaps onto the base of the container to form the stackable package. The top outer surface of the overcap lid includes a recessed panel which is correspondingly structured for engagement to the bottom surface of a base of another container in a stacked and stable relationship. The top container and the bottom container are not interlocked in the stacked relationship, in other words, all movement is not prevented, but the stacked relationship limits movement and increases stability.
In one embodiment, the bottom surface of the base includes protrusions which correspondingly mate with the four corners of a recessed panel of the top surface of a lid of another container. The corresponding geometry of the top surface of the overcap lid and the bottom surface of the base enhance “package to package” stacking, that is to say, stacked containers are more likely to maintain a stacked relationship when subject to vibration, shaking, twisting, or other destructive forces to the stack.
Improving stackability between containers has several advantages. The stacked inventive packages are easier to display, and are easier to merchandise with retailers, because, among other reasons, the improved stackability permits a broader range of stacking and displays. The stacked inventive packages also have improved home storage efficiency on a shelf, on a counter, or in the pantry. With improved stackability, the containers offer a reduction in damage and spills because of less falls from a stackable position. Further, by stacking a plurality of units to maximize containers per cubic feet, and by increasing the number of containers per stack height, the number of containers per shipping pallet is increased.
In one embodiment, the protrusions on the bottom of the base are convex and shaped like a hemisphere. The shape of the protrusion eliminates the point of contact between the lid on the lower container and the base on the upper container. The containers are not locked to a container above or below and are allowed limited sliding relative to an engaged container. Further, the stacked condition eliminates scuffing of the containers during the stacked condition.
As discussed herein, protrusions from the bottom of the base are correspondingly shaped to mate in a stacked relationship with a recess in the top surface of a lid of another container. In the illustrated embodiment, FIG. 2 shows hemisphere-shaped protrusions 62 a, 62 b, 62 c, 62 d located on the bottom surface of the base 12. In a stacked relationship between the two containers, one of each protrusions 62 a, 62 b, 62 c, 62 d is disposed within one of the corners 60 a, 60 b, 60 c, 60 d of a rectangle-shaped recess 60 of the top wall 48 of the below-positioned lid 16.
The base and the lid engaged beyond the convex protrusions. The recess 64 on the bottom wall 28 is generally rectangular-shaped and is surrounded by and defined by a ridge 70. The recess 60 on the top wall 48 of the lid 16 is also generally rectangular-shaped and is surrounded by and defined by a ridge 68. The top wall 48 of the lid is cooperatively shaped to insert into a rectangle-shaped recess 64 on the bottom wall 28 of the base 12, as seen in FIGS. 10 and 28. In a stacked relationship between a bottom container and a top container, the ridge 68 on the lid of the bottom container inserts with the inner diameter of the ridge 70 of the base 12 of the top container. As discussed herein, the sphere-shaped protrusions of the top container engage the recess corners of the lid of the bottom container to engage the top and bottom containers and generally promote stackability. It should be apparent to one skilled in the art that the number, shape, and size of the protrusions and the shape and size of the recess on the bottom wall of the base may vary in the practice of this invention.
Referring now to FIG. 28, portions of two containers are shown in a stacked position. FIG. 28 is an enlarged, sectional view of a portion of the base of FIG. 20, shown along the line 27-27 of FIG. 20 and with a second container in a stacked position above the first container. Specifically, the base 12 of the first container 10 is shown in a stacked position on top of a lid 16′ of a second container 10′. As discussed herein, the shape of the protrusions 62 c, 62 d decreases the point of contact between the lid 16′ on the lower container 10′ and the base 12 on the upper container 10. For example, the lid 16′ on the lower container 10′ and the base 12 on the upper container 10 do not contact each other for a length L₁between the two protrusions 62 c, 62 d, as shown in FIG. 28. Neither containers 10, 10′ is locked to a container above or below, and each container is allowed to slide generally in a horizontal direction relative to an engaged container. The stacked condition eliminates scuffing of the containers 10, 10′ during the stacked condition.
The present disclosure is directed to a base and lid which engage with each other to form a container. The container has certain inventive features which are advantageous to the manufacturing process prior to the filling of the powder in the base. The present disclosure relates to powder package container internal de-nesting ribs that allow the bases to nest inside one another when stored and empty, but also easily separate from one another when pulled apart. The base is designed with a slight draft angle on the vertical side walls which aid ejection from the injection molding tool. This draft angle also allows the containers to nest within one another when empty. If no denesting aid is utilized, the containers may completely nest until the base collars come in contact. When the bases are completely nested, a filler may experience difficulty in separating the containers because the side walls of each container are so closely aligned. As such, air has a difficult time escaping from the stack and a vacuum effect is created, which makes it difficult to separate the containers. However, when the vertical denesting ribs are positioned on the inside side walls near the bottom of the base to act as mechanical stops, the bases cannot nest completely. Without completely nesting, the bases have more space between the vertical side walls which allows air to evacuate and the bases to separate more easily.
In the performance nutrition powder protein and supplement market, packages typically include a round base container with a round threaded screw top closure. The round base containers do not nest inside one another when empty causing the container manufacture to ship the containers and lots of air to the filling facility. The present invention allows containers to be nested inside one another, improving inbound distribution and warehousing efficiencies, thus reducing costs by minimizing warehouse storage space of empty containers and reducing the number of truckloads required to ship empty containers to the filling facility. The present invention includes the use of internal denesting ribs that allow for easy separation at the filling facility when they are ready to fill the containers with product.
The base container and the internal denesting ribs will likely be manufactured in, but not limited to, a direct food contact approved polymer such as polyethylene or polypropylene. The manufacturing process for the container with denesting ribs will likely use, but is not limited to, an injection molding process. The containers will be injection molded, collected, and then nested together in predetermined stack quantities. The stacked and nested containers will be packed in secondary packaging and/or palletized for shipment to the filling facility. At the filling facility, the stacks of nested containers will be manually or automatically denested and placed on a conveyor travelling to the filling station.
FIG. 27 shows the internal denesting ribs in one of the inside corners of the base 12. The other three inside corners of the base (not shown) also include a pair of similarly shaped and spaced denesting ribs. As shown, the corner 80 b includes a pair of vertical ribs 82 b ₁and 82 b ₂. The ribs are vertically orientated, parallel and elongated. The exemplary base 12 includes two ribs per corner and has a total of 8 ribs per container. FIG. 13 shows the top portion of two different ribs 82 a ₁and 82 a ₂from a different corner 80 a. The top, inside container does not completely nest to the bottom base collar because the denesting ribs act as mechanical stops. As described, these stops hold the nested, inside container at a slightly higher position relative to a smooth wall, providing gaps between the side walls of the two containers to allow air to evacuate and ease the separation process. It should be understood by those with skill in the art that the denesting ribs on the base may be of a different number, shape, and size in the practice of this invention.
The lid includes another feature of the present invention which is advantageous to the manufacturing process prior to the filling of the powder in the base. The present disclosure relates to powder package lid which includes internal denesting structure that allow the lids to nest inside one another when stored and empty, but also easily separate from one another when pulled apart.
In the illustrated embodiment, the lids include wings located in each corner of the underside of the lid. The wings act as denesting structure when the lids are stacked inside each other. In order to maximize shipping efficiencies from the production molder to the filling facility, the lids may be nested inside each other during transit. Stacking allows the top lip to rest on the denesting ribs of the bottom lid, thus protecting the lid from dimensional deformation and allowing easy separation.
Referring now to FIGS. 15, 17, 19, and 28, the underside of the lid 16 includes four protruding wings 70 a, 70 b, 70 c, 70 d. The wings each protrude generally straight out from the underside of the center wall 48 of the lid and are generally curved from one edge to the other edge to match the generally flat area of the center wall 48. The top surface of each wing is also curved in a convex shape. It should be understood by those with skill in the art that the wings on the lid may be of a different number, location, shape, and size in the practice of this invention.
While various inventive aspects, concepts, and features of the general inventive concepts are described and illustrated herein in the context of various exemplary embodiments, these various aspects, concepts, and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the general inventive concepts. Still further, while various alternative embodiments as to the various aspects, concepts, and features of the inventions (such as alternative materials, structures, configurations, methods, circuits, devices and components, alternatives as to form, fit and function, and so on) may be described herein, such descriptions are not intends to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the general inventive concepts even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.

Claims

1. A container comprising:

a base defining an interior space and an opening to the interior space;

a lid removably attached to the base and adapted to cover the opening;

at least two latches attached to an outside surface of the lid, one of the at least two latches on one side of the lid and another of the at least two latches on an opposing side of the lid and each latch having at least one inwardly extending lug on an inside surface of the latch; and

at least two deflectors, one of the at least two deflectors on one side of the base and another of the at least two deflectors on an opposing side of the base and each deflector protruding from an outside surface of the base;

wherein at least each of the inwardly extending lugs is correspondingly positioned to contact one of the at least two deflectors during attachment of the lid to the base.

2. The container of claim 1, the base having a collar.

3. The container of claim 2, wherein movement of each of the inwardly extending lugs in a downward direction beyond the collar at one side of the base produces an audible engagement, with the at least one inwardly extending lug engaged to the base at an opposing side.

4. (canceled)

5. The container of claim 2, wherein each of the inwardly extending lugs defines a top horizontal surface, and the top horizontal surface of each of the inwardly extending lugs is positioned below the collar with the lid in a closed position.

6. The container of claim 2, wherein each of the inwardly extending lugs at one side of the base is movable in two directions along the outside surface of the collar with the lugs at the opposing side of the base engaged to the collar.

7. The container of claim 2, wherein each of the inwardly extending lugs at one side of the base is movable in two directions along the outside surface of one of the at least two deflectors with the lugs at the opposing side of the base engaged to the collar.

8. The container of claim 1, wherein each of the at least two deflectors comprises a plurality of spaced apart deflection ribs.

9. The container of claim 8, wherein each of the deflection ribs is vertically positioned and defines a lug engagement angle relative to the base.

10. (canceled)

11. The container of claim 8, wherein an outward facing surface of each of the deflection ribs is sloped downward.

12. (canceled)

13. The container of claim 2, further comprising a sealing flange defined by the base and a removable seal extending across the opening and attaching to the sealing flange.

14. The container of claim 13, the lid having a bead, wherein the bead is contiguous with the sealing flange with the lid in the closed position.

15. A container comprising:

a base defining an interior space and an opening to the interior space;

a lid removably attached to the base and adapted to cover the opening;

wherein the base has a collar and each of the inwardly extending lugs is positioned to nest underneath the collar with the lid in a closed position; and

wherein the at least two deflectors are positioned between the opening and the collar.

16. The container of claim 15, wherein each of the at least two deflectors comprises a plurality of spaced apart and vertically positioned deflection ribs.

17. The container of claim 16, wherein an outward facing surface of each of the deflection ribs is sloped downward to define a lug engagement angle relative to the base.

18-19. (canceled)

20. A container comprising:

walls defining an interior space and an upper portion, the upper portion defining a sealing flange having an internal edge which defines an opening to the interior space;

a lid removably attached to the upper portion and adapted to cover the opening;

a removable seal extending across the opening and attaching to the sealing flange, wherein the seal is positioned between the lid and the sealing flange;

at least two deflectors protruding from an outside surface of a wall, one of the at least two deflectors on one wall and another of the at least two deflectors on a non-contiguous wall.

21. The container of claim 20, the upper portion having a collar, wherein each of the inwardly extending lugs is positioned to nest underneath the collar with the lid in a closed position.

22. The container of claim 21, wherein movement of each of the inwardly extending lugs in a downward direction beyond the collar at one side of the base produces an audible engagement, with the at least one inwardly extending lug engaged to the base at an opposing side.

23-25. (canceled)

26. The container of claim 20, wherein each of the at least two deflectors comprises a plurality of spaced apart and vertically positioned deflection ribs.

27. The container of claim 26, wherein an outward facing surface of each of the deflection ribs is sloped downward to define an lug engagement angle relative to the base.

28. The container of claim 21, wherein the at least two deflectors are positioned between the opening and the collar