US20200223588A1

US20200223588A1 - Package with internal divider and outer closure

Info

Publication number: US20200223588A1
Application number: US16/245,931
Authority: US
Inventors: Andrew J. Blackmore; Marc R. Meyer
Original assignee: Display Pack Inc
Current assignee: Display Pack Inc
Priority date: 2019-01-11
Filing date: 2019-01-11
Publication date: 2020-07-16

Abstract

A package having an internal divider seated within a base and an outer closure. The divider defines a first compartment within an internal volume of the base, and the outer closure defines a second compartment between the divider and the outer closure. The base and divider are configured so that the divider snap-locks into the base.

Description

BACKGROUND OF THE INVENTION

The present invention relates to packaging and more particularly to thermoformed packaging for storing and transporting items such as food.
Thermoformed packaging is used in a wide variety of applications. The design and construction of thermoformed packaging typically varies from application to application. One common application for thermoformed packaging is food packaging. For example, fruits and vegetables are now commonly sold in containers made from thermoformed parts. Although food packages may vary in design and construction, one type of common food package includes a thermoformed base and a thermoformed lid that can be closed to cooperatively define an article-receiving space. In some applications, the base and lid are formed from a single portion of thermoplastic material and are joined together along a living hinge. In other applications, the base and lid are separately formed.
Typical thermoformed food packages have one article-receiving space. Attempts have been made to provide a food package with more than one article-receiving space in order to segregate food components within the package, such as by using internal cups or inserts which rest on shelves within the package. However, gasses can pass around such cups and inserts, transferring moisture and flavor between food components stored in different article-receiving spaces. These cups and inserts can even shift during storage or transport, causing leakage.

SUMMARY OF THE INVENTION

The present invention provides a package having a dual closure construction to provide a segregated internal volume.
The package can include a thermoformed base having a bottom, a peripheral wall extending upwardly from a periphery of the bottom and defining an open upper end, with the base defining an internal volume. A thermoformed inner divider can be seated within the base to define a first compartment within the internal volume, with the divider disposed below the open upper end of the base. An outer closure can close the open upper end of the base to define a second compartment between the divider and the outer closure. The base includes a snap-fit channel formed in at least a portion of the peripheral wall, below the open upper end and above the bottom of the base. The divider can be snap-locked to the base and includes a shoulder at a periphery of the divider received by the snap-fit channel.
In one embodiment, the divider is an inner lid configured to close the first compartment.
In one embodiment, the divider is configured to cover a portion of the base to from the first compartment. For example, the divider can extend over approximately half of the bottom of the base. In other embodiments, the divider can extend over less than half, less than ⅓, less than ¼, more than half, more than ⅔, or more than ¾ of the bottom of the base.
In one embodiment, the package can include a plurality of dividers. For example, a first divider can extend over approximately half of the base and a second divider can extend over the other half of the base. The two dividers may be configured to cooperatively fully close the first compartment or to cooperatively close less than the entire base.
In one embodiment, the divider can include a generally planar wall having a peripheral edge, with the shoulder at a periphery of the planar wall. The inner lid can further include a peripheral side extending upwardly from the periphery of the wall and forming the peripheral edge, with the shoulder formed on the peripheral side below the peripheral edge. The peripheral side can include a vertical portion and a horizontal portion above the shoulder, with the horizontal portion extending outwardly from an upper end of the vertical portion to form a peripheral lip extending around at least a portion of said divider, and said lip including said peripheral edge. The snap-fit channel can be formed by a channel shoulder defining an undercut that allows the channel to receive the shoulder on the divider, with the channel shoulder fitting closely against a top of the divider shoulder. The vertical portion can confront and extend above the channel shoulder, and the lip can overlie the channel shoulder.
In one embodiment, the snap-fit channel is an annular structure extending entirely around the periphery of the base, and the shoulder is an annular structure extending entirely around the periphery of the divider. The peripheral edge of the divider can have an outer shape that closely follows an inner shape of the peripheral wall of the base.
In one embodiment, the snap-fit channel is a U-shaped structure extending around a portion of the peripheral wall, and the shoulder is a U-shaped structure extending around a portion of the the periphery of the divider. The divider can comprise a free edge unattached to the base.
In one embodiment, the extent of the snap-fit channel exceeds that of the divider. In such embodiment, the divider may be installed in a range of positions defined by the snap-fit channel. In some embodiments, the position of the divider within the base may be varied by sliding the divider along the snap-fit channel.
In one embodiment, the outer closure comprises a thermoformed outer lid. The outer lid can be snap-locked to the base. The base can include a second snap-fit channel disposed above the first snap-fit channel for the divider, and the outer lid can have a shoulder received by the second snap-fit channel. The second snap-fit channel can be formed by a channel shoulder formed in the peripheral wall of the base and defining an undercut that allows the channel to receive the shoulder on the outer lid, with the channel shoulder fitting closely against a top of the shoulder on the outer lid.
In one embodiment, the outer closure comprises a film sealed with the base. The film can comprise at least one continuous layer of material that is airtight, and can optionally have a film thickness of 0.01-1.0 mm. The base can include a flange extending around at least a portion of the open upper end, outwardly from the peripheral wall, and a rim can be disposed on the flange. The film can be sealed to the rim. The rim can be an annular structure extending entirely around a periphery of the base, and can project upwardly with respect to the flange.
In one embodiment, a partition is provided on the divider to further divide at least one of the first or second compartment. The partition can be formed by an elongated concavity in a wall of the divider. The number, size, shape and arrangement of partitions may vary from application to application.
The present invention provides a simple packaging arrangement that provides improved functionality and can be readily integrated into a wide range of thermoformed packages. The use of a snap-in divider segregates the internal volume of the package and helps to ensure that the divider does not move or shift during storage and transport. Further, because the divider is snap-locked with the base, leakage around the divider can be minimized or even eliminated. The snap-lock also makes the divider easy to remove in order to access items below the divider. If desired, the divider can include a lifting tab making it even easier to remove the divider. The snap-lock arrangement may be configured to provide an audible indication when the divider snaps into the base.
These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.
Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, and any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a package in accordance with a first embodiment of the present invention;

FIG. 2 is an exploded perspective view of the package of FIG. 1;

FIG. 3 is a cross-sectional view of the package of FIG. 1;

FIG. 4 is an enlarged cross-sectional view of the package of FIG. 1 showing a snap joint between an inner lid and a base of the package;

FIG. 5 is a cross-sectional view of a package in accordance with a second embodiment of the present invention;

FIG. 6 is an exploded perspective view of a package in accordance with a third embodiment of the present invention;

FIG. 7 is an enlarged cross-sectional view of the package of FIG. 6 showing a divider of the package;

FIG. 8 is an exploded perspective view of a package in accordance with a fourth embodiment of the present invention;

FIG. 9 is a cross-sectional view of the package of FIG. 8.

DESCRIPTION OF THE CURRENT EMBODIMENT(S)

A package having a dual closure arrangement in accordance with a first embodiment of the present invention is shown in FIGS. 1-4. The package 10 includes a base 12, an inner closure or divider 14, and an external or outer closure 16. The base 12, inner divider 14, and outer closure 16 cooperatively define at least two internal spaces for receiving item(s) to be packaged. The base 12 defines an internal volume and an open upper end or opening 18 through which items can be placed into and removed from the base 12. The divider 14 is configured to cover or close a sub-portion of the internal volume to define a first or lower compartment 20 between the base 12 and the divider 14, which can be disposed below the opening 18. The outer closure 16 is configured to close the opening 18 in the base 12 and cover the divider 14 to define a second or upper compartment 22 between the divider 14 and the outer closure 16. Optionally, the compartments 20, 22 can be further subdivided, as described in more detail below.
The package can be use in packaging food, such as for a meal kit. When provided for a meal kit, components of a meal can be segregated or partitioned off from each other within the package, such as by placing components of the meal in different compartments 20, 22.
In the illustrated embodiment, the inner divider and outer closure 14, 16 are lids for closing openings into their associated compartments 20, 22. Optionally, the lids 14, 16 are removably coupled with the base 12 to close the openings into their associated compartments 20, 22, which can include fully or partially covering the openings. Alternatively, the lids 14, 16 can be hingedly coupled with the base 12. In one example, the package 10 can be a clamshell package in which the base 12 and outer lid 16 are joined along a living hinge.
The base 12 and lids 14, 16 can be made from a relatively rigid material such as polyethylene terephthalate (PET or PETE), although different materials may be used for each component 12, 14, 16 of the package 10. The use of a rigid material can provide stiffness and structural rigidity to the package 10.
The inner lid 14 can be selectively installed within the base 12 to define and close the lower compartment 20. In this embodiment, the inner lid 14 is configured to snap onto the base 12 via a snap-fit or snap-lock described in more detail below.
The outer lid 16 can be selectively installed on the base 12 to close the upper compartment 22, or in the absence of the inner lid 14, the package 10. In this embodiment, the outer lid 16 is configured to snap onto the base 12 and close the opening 18 of the base 12 via a snap-fit or snap-lock described in more detail below.
The compartments 20, 22 can be sized relative to each other in accordance with the package contents. In the illustrated embodiment, the lower compartment 20 is configured to contain the bulk of the packaged item(s) and therefore take up a majority of the internal volume defined by the base 12. Thus, the volume of the lower compartment 20 can be greater than the volume of the upper compartment 22. In other embodiments, the volume of each compartment 20, 22 can be equal or the volume of the lower compartment 20 can be less than the volume of the upper compartment 22.
The base 12 generally includes a bottom 24, a peripheral wall extending upwardly from a periphery of the bottom 24, which in the illustrated embodiment comprises a plurality of sidewalls 26, and a flange 28. The bottom 24, peripheral wall or sidewalls 26, and flange 28 can be integrally thermoformed from a single sheet of stock material. In this embodiment, the bottom 24 is generally rectangular and may include contours, as desired. For example, the bottom 24 of the base 12 may include a trough 30. The trough 30 may, among other things, provide a place to accumulate fluid, such as water that may run off of packaged fruits or vegetables. The trough 30 may also strengthen the base 12. The size, shape and configuration of the bottom 24 may vary from application to application, as desired. The trough 30 may be eliminated when not desired. For example, the base may alternatively be circular and may have a peripheral wall comprising a single circumferential sidewall extending upwardly from a circular bottom (not shown).
The sidewalls 26 extend upwardly from the periphery of the bottom 24. In this embodiment, the sidewalls 26 correspond in shape with the bottom 24. More specifically, the sidewalls 26 are generally rectangular, and can have a slight outward taper from bottom to top. The size, shape and configuration of the sidewalls 26 may vary from application to application, as desired.
The base 12 can include a snap-fit channel 29 for receiving the outer lid 16 formed in at least a portion of the sidewalls 26. The snap-fit channel 29 of this embodiment is an annular structure that extends entirely around the periphery of the base 12, including all sidewalls 26. In this embodiment, the snap-fit channel 29 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the sidewalls 26.
In the illustrated embodiment, the snap-fit channel 29 is formed by a shoulder 31 disposed toward the upper end of the sidewalls 26 and configured to provide a structure for snap-locking the outer lid 16 into place on the base 12. The shoulder 31 of this embodiment is an annular structure that extends entirely around the periphery of the package 10. In this embodiment, the shoulder 31 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the periphery of the package 10. As perhaps best shown in FIGS. 3 and 4, the base shoulder 31 may be formed to define an undercut 33 that allows the shoulder 31 to receive a corresponding shoulder 37 formed on the outer lid 16, as described in more detail below. The interaction of these shoulders 30 and 37 allows the outer lid 16 to be snap-locked onto the base 12. The size, shape and configuration of the shoulder 31, including undercut 33, may be varied to control the amount of force required to install the outer lid 16 on the base 12 and to separate the lid 16 from the base 12.
The flange 28 extends outwardly from the upper ends of the sidewalls 26, above the snap-fit channel 29, to form a peripheral lip extending around the top of the base 12. The flange 28 can extend at an angle of approximately 90 degrees relative to the sidewalls 26 along a plane generally parallel to the bottom 24.
Optionally, a rim 32 can be disposed on the flange 28. The rim 32 of this embodiment is an annular structure that extends entirely around the periphery of the base 12, projecting upwardly with respect to the flange 28. In this embodiment, the rim 32 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the periphery of the base 12.
As noted above, the outer lid 16 is configured to be fitted onto the base 12 to close the upper compartment 22. In the illustrated embodiment, the outer lid 16 includes a lid wall 34, a peripheral edge 36, a shoulder 37 at the periphery of the lid wall 34, and optionally a groove 38 at the peripheral edge 36. The lid wall 34, peripheral edge 36, shoulder 37, and optional groove 38 can be integrally thermoformed from a single sheet of stock material. The peripheral edge 36 is generally planar and is configured to lie against the horizontal portion of the flange 28 when the outer lid 16 is installed on the base 12. The shoulder 37 of the outer lid 16 extends downwardly into the base 12 to interlock with the shoulder 31 of the base 12. The lid shoulder 37 is sized and shaped to fit tightly within the base shoulder 31, thereby providing a firm interlock, an example of which is shown in FIG. 4. As the lid shoulder 37 snaps over the base shoulder 31, the snap action can optionally provide a distinctive snapping sound which provides an audible indication that the outer lid 16 has been secured to the base 12. In the illustrated embodiment, the lid 16, shoulder 37 and peripheral edge 36 are rectangular. The shoulder 37 of this embodiment is an annular structure that extends entirely around the periphery of the lid 16. In this embodiment, the shoulder 37 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the periphery of the lid 16.
The groove 38 of the outer lid 16 opens downwardly to receive the rim 32 of the base 12. The groove 38 is sized and shaped to fit tightly about the rim 32, thereby providing additional engagement between the outer lid 16 and base 12. The groove 38 of this embodiment is an annular structure that extends entirely around the periphery of the outer lid 16. In this embodiment, the groove 38 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the periphery of the outer lid 16. Alternatively, instead of having the groove 38 that receives the rim 32, the peripheral edge 36 of the outer lid 16 can terminate inside the rim 32. For example, the peripheral edge 36 can have an outer shape that closely follows the inner shape of the rim 32, and the spacing between the inside diameter of the rim 32 and the outside diameter of the peripheral edge 36 of the lid 16 may be small enough to make it difficult for a consumer to access the peripheral edge 36 for a tamper-resistant lid 16.
With the base 12 and outer lid 16 snap-fitted together, the upper compartment 22 can be relatively easily opened simply by lifting the outer lid 16 away from the base 12 with enough force to overcome the snap-fit engagement. Other options for securing the outer lid 16 to the base 12 are possible, such as permanently sealing (e.g. welding) the outer lid 16 to be base 12 to make it difficult to open and therefore tamper with the content of the package 10.
While not shown herein, the outer lid 16 can include a gripping structure, such as a tab, at the peripheral edge 36 which can extend outwardly beyond the flange 28 of the base 12 when the outer lid 16 is installed on the base 12 to assist in separating the outer lid 16 from the base 12. The outer lid 16 can optionally include a tamper evident seal (not shown) or other tamper-evident arrangement with the base 12 configured to reveal any interference with the contents of the package 10, and in the case of the outer lid 16, particularly with the contents of the upper compartment 22. The outer lid 16 can include additional contours, as desired, to provide strength or to implement aesthetic or functional features.
The inner lid 14 is configured to be fitted into the base 12 to define and close the lower compartment 20. In the illustrated embodiment, the inner lid 14 includes a generally planar wall 40 having a peripheral edge 42 and a shoulder 44 at the periphery of the lid wall 40. The lid wall 40, peripheral edge 42, and shoulder 44 can be integrally thermoformed from a single sheet of stock material. The peripheral edge 42 has an outer shape that closely follows the inner shape of the sidewalls 26 of the base 12. In the illustrated embodiment, the lid 14 and peripheral edge 42 are rectangular. The shoulder 44 of this embodiment is an annular structure that extends entirely around the periphery of the lid 14. In this embodiment, the shoulder 44 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the periphery of the lid 14.
The inner lid 14 can include a peripheral side 46 that extends upwardly from the periphery of the lid wall 40 and forms the peripheral edge 42 extending around the lid wall 40. The peripheral side 46 can extend at an angle of approximately 90 degrees relative to the lid wall 40 along a plane generally orthogonal to the bottom 24 of the base 12. The shoulder 44 can be formed on the peripheral side 46. The peripheral side 46 of this embodiment is an annular structure that extends entirely around the periphery of the inner lid 14, projecting upwardly with respect to the lid wall 40.
The peripheral side 46 can include a vertical portion 48 and a horizontal portion 50 above the shoulder 44. The horizontal portion 50 extends outwardly from the upper end of the vertical portion 48 to form a peripheral lip extending around the top of the inner lid 14. The horizontal portion or lip 50 can extend at an angle of approximately 90 degrees relative to the vertical portion 48 along a plane generally parallel to the lid wall 40 and to the bottom 24 of the base 12. The lip 50 can include the peripheral edge 42.
The base 12 can include a snap-fit channel 52 formed in at least a portion of the sidewalls 26. The snap-fit channel 52 of this embodiment is an annular structure that extends entirely around the periphery of the base 12, including all sidewalls 26. In this embodiment, the snap-fit channel 52 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the sidewalls 26.
The snap-fit channel 52 is spaced below the upper end of the base 12, which can be defined by the upper ends of the sidewalls 26, and more particularly can be defined by the flange 28 and/or rim 32 on the sidewalls 26. The snap-fit channel 52 can be provided on the sidewalls 26 at any location between the bottom 24 and the upper end of the base 12. With such spacing, the inner lid 14 is in turn located between the bottom 24 and upper end of the base 12, thereby providing space above and below the inner lid 14 for the compartments 20, 22.
In the illustrated embodiment, the snap-fit channel 52 is formed by a shoulder 54 projecting inwardly and defining an undercut 56 that allows the channel 52 to receive the shoulder 44 on the inner lid 14, with the shoulder 54 of the base 12 fitting closely against the top of the lid shoulder 44 and below the lip 50. The vertical portion 48 of the peripheral side 46 can be configured to confront and extend above the shoulder 54 on the base 12 and the lip 50 can be configured to overlie the shoulder 54 on the base 12. The interaction of the snap-fit channel 52 and lid shoulder 44 allows the inner lid 14 to be snap-locked in the base 12, below the upper end of the base 12, which can be defined by the upper ends of the sidewalls 26, and more particularly can be defined by the flange 28 and/or rim 32 on the sidewalls 26. The side, shape, and configuration of the channel 52, including the shoulder 54 and undercut 56, can be varied to control the amount of force required to install the inner lid 14 in the base 12 and to separate the inner lid 14 from the base 12. The shoulder 54 of this embodiment is an annular structure that extends entirely around the periphery of the base 12. In this embodiment, the shoulder 54 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the base 12.
The shoulder 44 of the inner lid 14 can extends radially outwardly relative to the lid wall 40 and vertical portion 48 to interlock with the channel 52 in the sidewalls 26 of the base 12. The shoulder 44 can be sized and shaped to fit tightly within the channel 52, thereby providing a snap-fit or snap-lock between the inner lid 14 and base 12. As the shoulder 44 snaps into the channel 52, the snap action can optionally provide a distinctive snapping sound which provides an audible indication that the inner lid 14 has been secured to the base 12.
With the base 12 and inner lid 14 snap-fitted together, the lower compartment 20 can be relatively easily opened simply by lifting the lid 14 away from the base 12 with enough force to overcome the snap-fit engagement. In some embodiments, the spacing between the inside diameter of the sidewalls 26 and the outside diameter of the peripheral edge 42 of the lid 14 may be small enough to make it difficult for a consumer to access the peripheral edge 42. Optionally, a lifting tab 58 can be provided on the inner lid 14 to assist in separating the inner lid 14 from the base 12. The lifting tab 58 can be provided on the peripheral edge 42 and can extend outwardly beyond the shoulder 44, and optionally outwardly beyond the lip 50 of the lid 14. A contour 60 can be formed in the tab 58 to provide a gripping structure to assist in lifting the inner lid 14 by the tab 58. The size, shape and configuration of the lifting tab 58 may vary from application to application. Other options for lifting the inner lid 14 from the base 12 are possible. In this embodiment, the lifting tab 58 is provided at a corner of the lid 14, but it can be located in other positions as desired. For example, the lifting tab 58 can be situated in a central portion of one of the sides of the lid 14.
The inner lid 14 can optionally include a tamper evident seal (not shown) or other tamper-evident arrangement with the base 12 configured to reveal any interference with the contents of the package 10, and in the case of the inner lid 14, particularly with the contents of the lower compartment 20. In one example, the tamper evident seal or other tamper-evident arrangement can be integrated with the lifting tab 58, such that lifting the lid 14 by the tab 58 breaks the tamper evident seal/arrangement.
The inner lid 14 can include additional contours, as desired, to provide strength or to implement aesthetic or functional features. For example, in the illustrate embodiment, the lid 14 includes a partition 62 that divides the upper compartment 22 into at least two separate upper compartments or sub-compartments 22A and 22B. The optional partition 62 can be formed by an elongated concavity 64 in the lid wall 40. The concavity 64 as shown includes spaced sides 66 projecting upwardly from the lid wall 40 and meeting at a top 68, which is optionally rounded. The sides 66 can face opposing portions of the upper compartment 22 and define portions of the sub-compartments 22A, 22B. The partition 62 can improve the strength and stability of the inner lid 14, which defines the bottom of the upper compartment 22 and may be required to support one or more item(s) to be packaged within the upper compartment 22.
The top 68 of the partition 62 can be spaced from or in contact with an underside 70 of the outer lid 16, which can be the underside 70 of the lid wall 34. In the illustrated embodiment, the underside 70 of the lid wall 34 is planar, and the top 68 just touches the planar underside 70. In other embodiments, the lid wall 34 can have a complementary contour with the partition 62, with the partition 62 extending above a planar portion of the lid wall 62. For example, if desired, the lid wall 34 can have a concavity configured to closely engage a portion of, or the entirety of, the concavity 64 forming the partition 62 to provide more complete segregation of the upper compartment 22. This can also provide additional strength and stability to the outer lid 16. Optionally, the partition 62 can have a snap-fit with the outer lid 16 for a sealed division between the sub-compartments 22A, 22B.
In this embodiment, the partition 62 is provided at a center of the inner lid 14 to generally bisect the inner lid 14 into equal halves, and thereby partition the upper compartment 22 into equally- sized sub-compartments 22A, 22B, but it can be located in other positions as desired. For example, the partition 62 can be offset on the inner lid 14 to divide the inner lid 14 into unequal halves. In an alternative embodiment, the partition 62 can project downwardly to partition the lower compartment 20. Additional partitions can be provided on the inner lid 14 to divide the either compartment 20, 22 even further.
Assembly of the package 10 will now be described with reference to FIGS. 1-4. When the inner lid 14 is installed on the base 12, the snap-fit interlock between the lid shoulder 44 and the base channel 52 hold the lid 14 securely within the base 12 to close the lower compartment 20. The inner lid 14 can be specifically snap-locked to an inner side surface 72 of the sidewalls 26, below the upper end of the base 12. The inner lid 14 and snap-lock joint between the inner lid 14 and the sidewalls 26 can be strong enough to support an item in the upper compartment 22 resting on top of the lid 14. Optionally, the snap-lock joint between the inner lid 14 and the sidewalls 26 can be liquid- and/or air-tight to prevent leakage of liquids and/or gasses from the lower compartment 20. Next, the outer lid 16 is installed on the base 12 to close the upper compartment 22. The outer lid 16 can be specifically snap-locked or otherwise attached to the upper end of base 12. Optionally, the snap-lock joint between the base 12 and the outer lid 16 can be liquid- and/or air-tight to prevent leakage of liquids and/or gasses from the upper compartment 22.
A package 10 having a dual closure arrangement in accordance with a second embodiment of the present invention is shown in FIG. 5, where like elements are identified with the same reference numerals. The second embodiment of the package 10 is substantially similar to the first embodiment described above with reference to FIGS. 1-4, save for the outer closure and features on the base 12 related to the outer closure. As illustrated, the outer closure can comprise a film 74 sealed with an upper part of the base 12, instead of a lid. The film 74 can more particularly be sealed to the rim 32 of the base 12. In other embodiments, the film 74 can be sealed to the flange 28 of the base 12. Optionally, the rim 32 on the base 12 can be wider than for the first embodiment in order to provide an appropriately-sized sealing surface for the film 74. Alternatively, the base 12 can include other contours for sealing the film thereto. In an embodiment where the inner lid 14 includes the partition 62, as shown, the top 68 of the partition 62 can be spaced from or in contact with an underside 76 of the film 74.
The film 74 can include an overhang 78 at a periphery of the film 74 which is not sealed to the base 12 to assist in separating the film 74 from the base 12. To open the upper compartment 22, the film 74 can be peeled away from the base 12 by gripping the overhang 78. Optionally, an outer lid (not shown) can be coupled with the base 12 over the film 74.
The film 74 can be at least one continuous layer or layers of material that is airtight and can also provide a gas and moisture barrier. The film 74 can be a laminate, with at least one additional layer being bonded together with the at least one continuous layer. In other embodiments, the film 74 can comprise a non-continuous layer or layers of material. The film 74 may be made from a polymer material such as polypropylene, or from a metallic foil, such as aluminum foil. The film 74 can comprise a thin film having a thickness of 0.01-1.0 mm.
The base 12 and inner lid 14 can be made from a relatively rigid material such as polyethylene terephthalate (PET or PETE), although different materials may be used for the base 12 and lid 14. The use of a rigid material for at least the inner lid 14 can add stiffness and structural rigidity to the package 10, particularly on packages where the film 74 is used as the outer closure.
Assembly of the package 10 can be substantially similar for the second embodiment as the first, save for that the film 74 is sealed with the base 12 after snap-fitting the inner lid 14 in place. Sealing of the film 74 can comprise attaching or bonding the film 74 to the base 12, such as to the rim 32 or flange 28 of the base 12. Optionally, the film 74 can be hermetically sealed to the base 12.
A package 10 having a dual closure arrangement in accordance with a third embodiment of the present invention is shown in FIGS. 6-7, where like elements are identified with the same reference numerals. The third embodiment of the package 10 is substantially similar to the second embodiment described above with reference to FIG. 5, save for the inner closure or divider 80 and its corresponding snap features of the base 12. As illustrated, the divider 80 cooperatively defines, along with the film 74, at least two internal spaces for receiving item(s) to be packaged. In the illustrated embodiment, the inner divider is a shelf which covers a sub-portion of the bottom 24 of the base 12, instead of the entire bottom 24.
In the illustrated embodiment, the divider 80 extends over approximately half of the bottom 24 of the base 12. In other embodiments, the divider 80 can cover other portions of the base 12 as desired. For example, the divider 80 can extends over less than half of the bottom 24 of the base 12, less than ⅓ of the bottom 24 of the base 12, less than ¼ of the bottom 24 of the base 12, more than half of the bottom 24 of the base 12, more than ⅔ of the bottom 24 of the base 12, or more than ¾ of the bottom 24 of the base 12. Additional dividers can be provided for the package 10 to divide the internal volume of the base 12 even further.
The base 12 and divider 80 can be made from a relatively rigid material such as polyethylene terephthalate (PET or PETE), although different materials may be used for the base 12 and divider 80. The use of a rigid material for at least the divider 80 can add stiffness and structural rigidity to the package 10, particularly on packages where the film 74 is used as the outer closure. Optionally, instead of the film 74, the package 10 can comprise a lid for the outer closure, for example the lid 16 as shown in FIGS. 1-4.
The inner divider 80 is configured to cover or close a sub-portion of the internal volume of the base 12 to define the first or lower compartment 20 between the base 12 and the divider 80, which can be disposed below the opening 18. The film 74 is configured to close the opening 18 in the base 12 and cover the divider 80 to define the second or upper compartment 22 between the divider 80 and the film 74. Optionally, the compartments 20, 22 can be further subdivided, such as by the provision of partitions on the divider 80 or by the provision of additional dividers 80.
Optionally, the divider 80 is removably coupled with the base 12 to define the lower compartment 20, which can include fully or partially closing the lower compartment 20. Alternatively, the divider 80 can be hingedly coupled with the base 12. In this embodiment, the divider 80 is configured to snap onto the base 12.
The divider 80 is configured to be fitted into the base 12 to define the lower compartment 20. In the illustrated embodiment, the divider 80 includes a generally planar wall 82 having a peripheral edge 84 and a shoulder 86 at the periphery of the wall 82. The lid wall 82, peripheral edge 84, and shoulder 86 can be integrally thermoformed from a single sheet of stock material. In the illustrated embodiment, the divider 80 and peripheral edge 42 are rectangular. The peripheral edge 84 has an outer shape that closely follows the inner shape of a portion of the peripheral wall or sidewalls 26 of the base 12.
The shoulder 86 of this embodiment is a U-shaped structure that extends around a portion of the periphery of the divider 80, including a portion of three sides of the divider 80. More particularly, the shoulder 86 can extend around three sides of the divider 80, leaving a fourth side of the divider 80 without a shoulder. This fourth side of the divider 80 defines a free side or edge 100, described in further detail below. In this embodiment, the shoulder 86 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the periphery of the divider 80.
The divider can include a peripheral side 88 that extends upwardly from the periphery of the wall 82 to form the peripheral edge 84 extending around the wall 82. The peripheral side 88 can extend at an angle of approximately 90 degrees relative to the wall 82 along a plane generally orthogonal to the bottom 24 of the base 12. The peripheral side 88 of this embodiment is an annular structure that extends entirely around the periphery of the divider 88. Where present, the shoulder 86 can be formed on the peripheral side 88.
The peripheral side 88 can includes a vertical portion 90 and a horizontal portion 92. The horizontal portion 92 extends outwardly from the upper end of the vertical portion 90 to form a peripheral lip extending around the top of the divider 80. The horizontal portion or lip 92 can extend at an angle of approximately 90 degrees relative to the vertical portion 90 along a plane generally parallel to the wall 82 and to the bottom 24 of the base 12. The lip 92 can include the peripheral edge 84. The vertical portion 90 can extend upwardly from the shoulder 86 where present, while along the free edge 100, which does not include the shoulder 86, the vertical portion 90 can extend upwardly directly from the divider wall 82.
The base 12 can include a snap-fit channel 94 formed in at least a portion of the peripheral wall or sidewalls 26. The snap-fit channel 94 of this embodiment is a U-shaped structure that extends around a portion of the periphery of the base 12, including a portion of three of the sidewalls 26. For example, the U-shaped channel 94 can extend approximately halfway around the periphery of the base 12, such that the divider 80 is snap-locked to approximately half of the base 12. In this embodiment, the snap-fit channel 94 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the three sidewalls 26.
The snap-fit channel 94 can be sized according to the size of the divider 80, particularly having a length commensurate with the length of the shoulder 86 or alternatively, the extent of the snap-fit channel 94 can exceed that of the divider 80 or its shoulder 86. In such embodiment, the divider 80 may be installed in a range of positions defined by the snap-fit channel 94. In some embodiments, the position of the divider 80 within the base 12 may be varied by sliding the divider 80 along the snap-fit channel 94.
The snap-fit channel 94 is spaced below the upper end of the base 12, which can be defined by the upper ends of the sidewalls 26, and more particularly can be defined by the flange 28 and/or rim 32 on the sidewalls 26. The snap-fit channel 94 can be provided on the sidewalls 26 at any location between the bottom 24 and the upper end of the base 12. With such spacing, the divider 80 is in turn located between the bottom 24 and upper end of the base 12, thereby providing space above and below the divider 80 for the compartments 20, 22.
In the illustrated embodiment, the snap-fit channel 92 is formed by a shoulder 96 projecting inwardly and defining an undercut 98 that allows the channel 92 to receive the shoulder 86 on the divider 80, with the shoulder 96 of the base 12 fitting closely against the top of the divider shoulder 86 and below the lip 92. The vertical portion 90 of the peripheral side 88 can be configured to confront and extend above the shoulder 96 on the base 12 and the lip 92 can be configured to overlie the shoulder 96 on the base 12. The interaction of the snap-fit channel 94 and divider shoulder 86 allows the inner divider 80 to be snap-locked in the base 12, below the upper end of the base 12, which can be defined by the upper ends of the sidewalls 26, and more particularly can be defined by the flange 28 and/or rim 32 on the sidewalls 26. The size, shape, and configuration of the channel 92, including the shoulder 96 and undercut 98, can be varied to control the amount of force required to install the inner divider 80 in the base 12 and to separate the inner divider 80 from the base 12. The shoulder 96 of this embodiment is a U-shaped structure that extends around a portion of the periphery of the base 12, including a portion of three of the sidewalls 26. In this embodiment, the shoulder 96 is continuous, but it may be discontinuous or otherwise extend through only one or more portions of the three sidewalls 26.
The shoulder 86 of the inner divider 80 can extends radially outwardly relative to the wall 82 and vertical portion 90 to interlock with the channel 92 in the sidewalls 26 of the base 12. The shoulder 86 can be sized and shaped to fit tightly within the channel 94, thereby providing a snap-fit or snap-lock between the inner divider 80 and base 12. As the shoulder 86 snaps into the channel 94, the snap action can optionally provide a distinctive snapping sound which provides an audible indication that the inner divider 80 has been secured to the base 12.
With the base 12 and inner divider 80 snap-fitted together, the divider 80 can be relatively easily removed simply by lifting the divider 80 away from the base 12 with enough force to overcome the snap-fit engagement. The free edge of the divider 80 makes it easy for a consumer to grip the divider 80 for removal. Alternatively, a lifting tab can be provided on the divider 80 to assist in separating the divider 80 from the base 12. The inner divider 80 can include additional contours, as desired, to provide strength or to implement aesthetic or functional features. For example, the divider 80 can include a partition that divides the lower and/or upper compartments 20, 22 into separate compartments or sub-compartments.
As described above, the divider 80 can be a shelf supported on multiple sides by a snap-lock with the sidewalls 26 of the base 12 and having free end 10 which is unattached to the base 12. The shelf can support one or more item(s) in the second compartment 22, with the free edge 100 generally defining a border or boundary of the second compartment. The first compartment 20 can extend below the shelf, and beyond the free edge 100 to be bounded by the sidewalls 26 of the base 12. It is noted that items in the first compartment 20 beyond the free edge 100 can extend upwardly next to and above the divider 80. The compartments 20, 22 can be sized relative to each other in accordance with the package contents.
In the illustrated embodiment, the compartments 20, 22 defined within the package 10 are open to each other. One or more item (2) can be supported in the first compartment by the bottom wall 24 of the base, and one or more item(s) can be supported in the second compartment 22 on the divider 80. The first compartment 20 can extend below the divider 80, as well as next to the divider 80, particularly next to the free edge 100 of the divider 10. Optionally, the open space lateral of the divider 80 can define a third compartment within the package 10.
The free edge 100 of the divider 80 is unattached to the base 12. The free edge 100 can extent between two of the sidewalls 26 of the base, and be spaced from, and optionally parallel to, the sidewall 26 of the base 12 which does not comprise the channel 94.
Optionally, the compartments 20, 22 can be closed off from each other by the divider 80, such as by having an extension on the free edge 100. The extension can project downwardly toward the bottom 24 of base 12 to close a lateral side of the first compartment 20 and/or upwardly toward the opening 18 of the base 12 to close a lateral side of the second compartment 22.
Assembly of the package 10 will now be described with reference to FIGS. 6-7. When the inner divider 80 is installed on the base 12, the snap-fit interlock between the shoulder 86 and the base channel 94 hold the divider 80 securely within the base 12 to at least partially cover the lower compartment 20 and define the upper compartment 22. The divider 80 can be specifically snap-locked to the inner side surface 72 of the sidewalls 26, below the upper end of the base 12. The divider 80 and snap-lock joint between the divider 80 and the sidewalls 26 can be strong enough to support an item in the upper compartment 22 resting on top of the divider 80. Next, the film 74 is sealed with the base 12. Sealing of the film 74 can comprise attaching or bonding the film 74 to the base 12, such as to the rim 32 or flange 28 of the base 12. Optionally, the film 74 can be hermetically sealed to the base 12.
A package 10 having a dual closure arrangement in accordance with a fourth embodiment of the present invention is shown in FIGS. 8-9, where like elements are identified with the same reference numerals. The fourth embodiment of the package 10 is substantially similar to the third embodiment described above with reference to FIGS. 6-7, except the package 10 is shown as including a plurality of dividers 80A, 80B and corresponding snap- fit channels 94A, 94B in the base 12. For example, a first divider 80A can extend over approximately half of the base 12 and a second divider 80B can extend over the other half of the base 12. The two dividers 80A, 80B may be configured to cooperatively fully close the first compartment 20 or to cooperatively close less than the entire base 12, optionally leaving the first compartment 20 at least partially open to the second compartment 22. Additional dividers can be provided for the package 10 to divide the internal volume of the base 12 even further. Optionally, the compartments 20, 22 can be further subdivided, such as by the provision of partitions on either or both of the dividers 80A, 8B.
As illustrated, the dividers 80A, 80B are removably coupled with the base 12 to define the lower compartment 20 and to together full close the lower compartment 20, with the horizontal portions or lips 92A, 92B at the free edges 100A, 100B touching, or nearly so. Alternatively, the free edges 100A, 100B can be spaced apart. The dividers 80A, 80B can collectively form a lid for closing the opening to the lower compartment 20, although either divider 80A, 80B can individually form a lid as well. The dividers 80A, 80B can be individually snapped onto the base, with the first divider 80A snap-locked via a first snap-fit channel 94A and the second divider 80B snap-locked via a second snap-fit channel 94B.
The channels 94A, 94B can be separate channels sized according to the size of the divider 80A, 80B, particularly having a length commensurate with the length of the shoulder 86A, 86B thereof, or alternatively, the extent of the snap- fit channels 94A, 94B can exceed that of the dividers 80A, 80B or shoulder 86A, 86B. In yet another alternatively, one continuous channel similar to channel 52 shown in FIG. 2, can be provided in the base 12, with the dividers 80A, 80B snapping into portions of the channel.
With the base 12 and dividers 80A, 80B snap-fitted together, the lower compartment 20 can be relatively easily opened simply by lifting one or both of the dividers 80A, 80B away from the base 12 with enough force to overcome the snap-fit engagement. In some embodiments, the spacing between the inside diameter of the sidewalls 26 and the outside diameter of the peripheral edges 84A, 84B of the dividers 80A, 80B may be small enough to make it difficult for a consumer to access the peripheral edge 84A, 84B. Optionally, a lifting tab (not shown) can be provided on one or both of the dividers 80A, 80B to assist in separating the dividers 80A, 80B from the base 12. The lifting tab can be similar to the lifting tab 58 shown in FIG. 2, and can be provided on the peripheral edge 84A, 84B and can extend outwardly beyond the shoulder 86A, 86B. The size, shape and configuration of such a lifting tab may vary from application to application. Other options for lifting the dividers 80A, 80B from the base 12 are also possible. The dividers 80A, 80B can include additional contours, as desired, to provide strength or to implement aesthetic or functional features.
Assembly of the package 10 will now be described with reference to FIGS. 8-9. When the first divider 80A is installed on the base 12, the snap-fit interlock between the shoulder 86A and the base channel 94A hold the divider 80A securely within the base 12 to partially cover the lower compartment 20. Next, the second divider 80B is installed on the base 12, with the snap-fit interlock between the shoulder 86B and the base channel 94B holding the divider 80B securely within the base 12 to cover the remainder of the lower compartment 20. The dividers 80A, 80B can be specifically snap-locked to the inner side surface 72 of the sidewalls 26, below the upper end of the base 12. It is noted that the second divider 80B can be installed prior to the first divider 80A. The dividers 80A, 80B and snap-lock joints between the dividers 80A, 80B and the sidewalls 26 can be strong enough to support an item in the upper compartment 22 resting on top of the dividers 80A, 80B. Next, the film 74 is sealed with the base 12. Sealing of the film 74 can comprise attaching or bonding the film 74 to the base 12, such as to the rim 32 or flange 28 of the base 12. Optionally, the film 74 can be hermetically sealed to the base 12.
Although the present invention is described in connection with a package 10 intended for use in packaging food, such as meal kits, the present invention may be implemented in connection with packages intended for use in packaging other items. The size, shape and configuration of the package may vary from application to application, as desired. For example, the width, depth or shape of the base 12, lids 14, 16, film 74 or divider 80 may be varied to accommodate essentially any item or items to be packaged. In the illustrated embodiments, the package 10 is generally rectangular in shape, and the base 12 is relatively deep and the lids 14, 16, film 74 and divider 80 are relatively shallow. However, the present invention may be incorporated into packages of essentially any size or shape. For example, the base may alternatively be circular and may have a peripheral wall comprising a single circumferential sidewall extending upwardly from a circular bottom (not shown). The illustrated packages 10 are intended to provide point-of-sale or point-of-purchase packaging for articles, and may be disposable, but the present invention may be implemented in other types of packaging, if desired.
Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used herein to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).
The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A package comprising:

a thermoformed base having a bottom, a peripheral wall extending upwardly from a periphery of said bottom and defining an open upper end, said base defining an internal volume;

a thermoformed inner divider seated within said base to define a first compartment between said bottom and said divider within said internal volume, said divider disposed below said open upper end; and

an outer closure on said base and closing said open upper end to define a second compartment between said divider and said outer closure;

wherein said base includes a snap-fit channel formed in at least a portion of said peripheral wall, below said open upper end of said the base and above said bottom of said base; said snap-fit channel spaced below said outer closure seated on said base; and

wherein said divider is snap-locked to said base and includes a shoulder at a periphery of the divider received by said snap-fit channel.

2. The package of claim 1 wherein said divider comprises an inner lid configured to close said first compartment.

3. The package of claim 1 wherein said divider includes a generally planar wall having a peripheral edge and said shoulder at a periphery of said wall.

4. The package of claim 3 wherein said divider includes a peripheral side extending upwardly from the periphery of said wall and forming said peripheral edge, wherein said shoulder is formed on said peripheral side below said peripheral edge.

5. The package of claim 4 wherein said peripheral side includes a vertical portion and a horizontal portion above said shoulder, said horizontal portion extending outwardly from an upper end of said vertical portion to form a peripheral lip extending around at least a portion of said divider, and said lip including said peripheral edge.

6. The package of claim 5 wherein said snap-fit channel is formed by a channel shoulder formed in the at least a portion of said peripheral wall, said shoulder defining an undercut that allows said channel to receive said shoulder on said divider, with said channel shoulder of said base fitting closely against a top of said shoulder on said divider.

7. The package of claim 5 wherein said vertical portion confronts and extend above said channel shoulder of said base and said lip overlies said channel shoulder of said base.

8. The package of claim 3 wherein said snap-fit channel is an annular structure extending entirely around the periphery of said base, and said shoulder is an annular structure extending entirely around the periphery of said wall.

9. The package of claim 8 wherein said peripheral edge has an outer shape that closely follows an inner shape of said peripheral wall of said base.

10. The package of claim 3 wherein said snap-fit channel is a U-shaped structure extending around a portion of said peripheral wall, and said shoulder is a U-shaped structure extending around a portion of said the periphery of said divider, and wherein said divider comprises a free edge unattached to said base.

11. The package of claim 1 wherein said divider extends over one of: approximately half of said bottom of said base; less than half of said bottom of said base; less than ⅓ of said bottom of said base; less than ¼ of said bottom of said base; more than half of said bottom of said base; more than ⅔ of said bottom of said base; or more than ¾ of said bottom of said base.

12. The package of claim 1 wherein said outer closure comprises a thermoformed outer lid snap-locked to said base.

13. The package of claim 12 wherein said snap-fit channel is a first snap-fit channel, and said base includes a second snap-fit channel disposed above the first snap-fit channel, and wherein said outer lid includes a shoulder received by said second snap-fit channel.

14. The package of claim 13 wherein said second snap-fit channel is formed by a channel shoulder formed in said peripheral wall, said shoulder defining an undercut that allows said channel to receive said shoulder on said outer lid, with said channel shoulder fitting closely against a top of said shoulder on said outer lid.

15. The package of claim 1 wherein said outer closure comprises a film sealed with said base, and wherein said film comprises at least one continuous layer of material that is airtight, and wherein said film has a thickness of 0.01-1.0 mm.

16. The package of claim 15 wherein said base includes a flange extending around at least a portion of said open upper end, outwardly from said peripheral wall, and a rim disposed on said flange, wherein said film is sealed to said rim.

17. The package of claim 1 wherein said divider comprises a lifting tab provided on said periphery of said divider and extending outwardly beyond said shoulder.

18. The package of claim 1 wherein said divider comprises a partition dividing said second compartment into at least two separate sub-compartments.

19. The package of claim 18 wherein said divider includes a generally planar wall having a peripheral edge, and said partition is formed by an elongated concavity in said wall.

20. The package of claim 1 wherein said shoulder is configured to snap into said channel to provide an audible indication that said divider has been secured to said base.